I've almost rebuilt my front-end completely minus the wheel hubs. But I was having a problem with bad mpg and the truck randomly wandering all over the road. Well... I didn't have the problem until after I put a new passengers side cv axle in. The axle is my culprit. The new one is longer then my original one. So when I tightened all the balljoints and put everything together. The cv axle seems to catch when I rotate the wheel. But as soon as I pop loose a ball joint. Everything turns freely.
Now for the weird problem... I thought maybe it was just a messed up new cv axle. But I took it to two parts stores and they are all longer like the new one. I however did turn my torsion bars down to try and get some better mpgs. Maybe my only solution is to turn them back up and raise my truck back up? I do have poly bushings in the front, I thought maybe with those and the alignment shop setting the alignment. Maybe my suspenaion is too tight?

 

What exactly is your problem? As for the CV shaft being "too long" you probably don't have it popped into the c-clip retainer or the splines might not be lined up so it sticks out too far. The wandering was probably caused by a combination of turning in the torsion bars and separating BOTH ball joints which can cause misalignment.

 

The problem seems to be that the new cv axle is alittle longer overall than my old one. And with everything installed, and put in. If I turn the wheel hub, it will turn 1/2 a turn and get tight. And then I can see the cv axle get in a bind an kind pop. And I can turn freely until that spot again. But I recently had everything aligned at the raised height after I put all new bushings, and balljoints in. I lowered the truck back down to stock height (with the old alignment), So it might be my problem. I won't get to work on it until the weekend.
It never caused major problems. It just was causing some bad gas mileage, and weird handling on un-even pavement. I never really payed attention to it. But I wonder if there's any bushings or bent brackets on the diff itself? I bought the truck used and I know it has hit something with the passengers front side lower. But it hasn't always had this problem.

 

If you adjust the torsion bars you need to have your car re-aligned. My bump stops were worn and would allow the wheels to drop too far. I'd hit bumps and it would cause the cvs to bind. The front wheels would also bind at the cv axle when the front end was lifted with a jack. I'd check your upper bump stops and make sure they're intact.