[Brian T]

Hello Will N,
Looks like you covered every thing, page 283 in the service bulletins may have the answer, it explains why the steering arm angles were changed, I had the right tire only scuffing out regardless of the toe in set correctly, the left side was either bent or an early arm in its place, there was 1" of space between the tie rod end and back plate, the other side was about a 1/4".

I have always wondered if the vendors that re-ball these parts ever check them, someone ending up with worn tires.