2 things:
Second: I get a clunk when driving over bumps that sounds like one or more bushings are worn. A friend also noticed. The sound is louder coming from the front passenger side. It is noticeable even when driving over bumps as small as frost heaves across a relatively new road. It is not super loud though.
In addition to what was replaced during the lift (subframe bushings), I've also replaced the sway bar bushings and end-links, idler arms, engine mounts, and front shocks. While doing the alignment, I asked the mechanic to take a look for tired bushings and he demonstrated that the lower bushing on the shock seemed quite soft when he pushed/bounced on the car. I now think they were just not torqued to spec, regardless they are replaced.
In my driveway, I can't replicate the clunk by rocking the vehicle. Nothing feels loose when I grab or lever on it (ball joints, tie rods, pitman, sway bar, etc). I laid under the van to feel the control arms and steering mechanism as my wife turned the wheels side-to-side and everything felt good. And when jacked, there is no play if I pry on the wheels side-to-side or up-and-down.
I can't figure it out. Maybe you can help?
I've taken a bunch of video of different bushings while rocking the car. Do these bushings look good to you?
Passenger Side LCA
Fore:
https://photos.app.goo.gl/TPTj17HG9bDPXmxp6
Aft:
https://photos.app.goo.gl/xPt9Rwtf8JWpduWp6
Passenger Side UCA
Fore:
https://photos.app.goo.gl/gtnKUy5nn1jjvUHT8
Aft:
https://photos.app.goo.gl/qYSJimimkFf4DXfu7
Driver Side LCA
Fore:
https://photos.app.goo.gl/C8bRtsYcE9dFLAGD6
Aft:
https://photos.app.goo.gl/TAMCK2rejUTQ9KmX8
Passenger Side Swaybar endlink and lower shock mount:
https://photos.app.goo.gl/pP7HgQPxv8qiX5tu5
Passenger Side Lower ball joint:
https://photos.app.goo.gl/8NYVjEdWjTUQNJP16
---------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------------------
First (I wanted the help before the photo share and tell): Performed the Wimpie 2+1 lift. I didn't intend to do the +1 part, but the driver side sat about 1" higher than the passenger side. When I checked the torsion bars, the driver's side adjustment bolt was about 1" farther than the passenger. So I leveled it out and then got an alignment. Also, the S10 springs raised the back end so high it looked ridiculous.
I didn't get a lot of photos, but then half the people on this board have done this mod.
Front went smoothly, but slow. Trimming the fan shroud with the cut-off and grinding disks for the angle grinder.
Attaching the radiator hose so it doesn't get caught in the fan.
Jacking the front to lift the frame from subframe.
Jacking the rear to swap leaf springs.
Some issues with drilling a straight hole for the rear strut relocation.
I relocated the front bumper using some 1/4" thick x 1' wide steel bar stock. Similarly, made extended brackets for the rear brake lines. I also threw on a Hellwig rear sway bar.
All-in-all. This gave me 3" of lift in the front and about 4.5" in the rear.