This is a long read but I really need advice here.
I have a 2005 ram 1500 hemi 4x4 quad cab short bed. The truck was rear ended while parked, It was on the lower left rear side and pushed the truck about 20ft. The truck needed a new left bed side taillight and tailgate, bumper. We measured the frame from every point every thing checked out fine. I drove it before the repair it drove great. about a month after repairs the truck develops a vibration in the front. Went to get a alignment it aligned all in the green but the upper caster is maxed out (inward). Took it to a Frame and alignment shop they said frame was possibly rolled in at the top. Also said the frame may have "settled" a week or so after the wreck. I have never heard/seen this. They also stated that it needed new upper & lower ball joints and steering rack bushings. I have had three different frame guys from different shops check/measure the frame no damage found. Also if the frame is rolled in that would articulacy allow more adjustment. The vibration is slight mostly noticeable on older/unkempt roads The history of this truck 70k miles immaculately kept up condition. EZ lift level kit installed 2-3 years/ 20k miles ago nitto grapple tires on 20in stock wheels. We tore down the front suspension the ball joint wore shot and the tie rod ends have a good amount of play.The steering rack bushings where fine but I went ahead and installed energy suspension poly ones. The brakes are "glazed" any thought suggestions? Does any one believe a rear end hit could cause all this months later? The trucks owner said it was fine before the wreck no reason to doubt that. I ended up replacing the entire front end upper lower ball joints tie rods, brakes, longer shocks for the level kit. installed caster kit. It is now aligned all in the green and drives great no vibration. I have read and been told the leveling kit/ tires can be hard on the suspension. Has anyone had this issue in the past? Was this a quick fix that will only come back? Any help is greatly appreciated! Thanks

 

I'm not sure of what you mean by "the upper caster is maxed out inwards" but i think I get it a little. I'm assuming you're reading an alignment printout where the front axle is the upper set of bar graphs, and the spec was towards the inside of the page?

Caster and camber are affected by leveling kits. Caster especially, when you lift the front end the caster goes positive(inwards on the page), they should have been able to adjust it, since every ram ive ever put on my alignment rack has had factory adjustment cams for camber and caster... Tie rods being worn and worn ball joints will cause a vibration, bump steer, memory steer, and a steering pull among other things.

I think you assessed the problem correctly and fixed it, not just a temporary fix. Yes larger tires and leveling kits will cause increased wear on the suspension and brakes. Especially brake rotor warping problems and wheel bearings burning up from the increased strain.

 

Thanks. What I meant by "the upper caster is maxed out inwards" is where the upper arm bolts to/adjust on the frame (the slotted holes) before the adjustment was all the way in (towards motor). This is where the caster kit was installed.