Because they "fix" it with the exact same crappy shaft. They fail all the time. Most folks who are out of warranty (and even some still covered) cut a small slit in the boot and put in 5th wheel grease. After the grease is added, they work the steering wheel back and forth. This seems to fix the issue for a while, but is also not a permanent solution as far as I know. I have also read a report of someone putting too much grease in the boot which then somehow caused the boot to explode when underhood temps rose.
'11 JKU Sport - TF Leveling Kit - 16" Strike 5s on 33s
What do you think about it being related more to jeeps that have been lifted than those that have not? I remember you are running the HD coils correct however it might be more prevalent in those jeeps at or above 2.5" of height.
98 XJ 02 TJ 10 JK 13 JK
2013 JK - Lifted w/ 35s - Bilstein 5100s - Monster TB - Chopped Flares - Can't Keep It Clean
Mine was stock at the time. I bought a grease gun and needle fitting and really stuffed the boot. Was not too bad. Just a minor feeling in the wheel/peddle. I read a entire thread about guy crying about his steering box. How crappy the JK's steering box is, he's had it replaced like 3 or 4 times.. blames the box and not the shaft for the noises/feelings that are common.
Hate to he his dealer
2007 Rubicon/Rock Krawler triple rate 2.5" coils/RK rear TB w/ a teraflex raised bracket/Rancho 9000 31/32XL shocks/Synergy flipped draglink,ball joints,tie rod /Hankook MT 315-75-16 on Level 8 ZX's/Rancho geo brackets/Ruff stuff uppers/Fox ATS stabilizer/Adams front DS/Artec front armor w/ Currie upper bushings/Rancho cat back exhaust.