Alignment issues after suspension rebuild & tie rod replacement. Help!

Earlier in the post:
Timeline
05/29/23: Outer tie rods blew after putting on spidertrax 1.5" spacers. My understanding is that spacers do not affect alignment. I noticed that after I got an alignment done that I had very little threads left. Part numbers are below and here you can see the before and after:

Part NumberPart NamePriceQuantityTotal

• 45047-39175 Tie Rod End | Driver Side | 1998-2004 Tacoma 4WD and PreRunner $53.81 1 $53.81
• $73 Genuine Toyota 45046-39295 Tie Rod End Sub-Assembly
  45046-39295 Tie Rod End | Passenger Side | 1998-2004 Tacoma 4WD and PreRunner $53.81 1 $53.81
• 45503-39075 Steering Tie Rod End $189.89 2 $379.78

While I do agree it is a bit premature and yes I need to install the correct PN LBJ's, I do not see any harm in excluding the possibility. The tie rods being maxed out was already an issue before changing ball joints. I'm just asking how someone could also visually inspect.

 

It is almost impossible to visually inspect for a bent spindle. When they do bend it will be at the weakest spot, the right angle at the top of the spindle where the UBJ is mounted. I can't see how a bend in that location would effect the exposed thread count on both Otres. And it seems even more unlikely that both spindles would be bent equally.

On the other hand, the location of the Otre mounting hole on the LBJ will directly determine where the Otre and Itre interface is.

 

I am currently experiencing this exact same thing. 03 PreRunner DoubleCab 3.4L. I replaced both UBJs, LBJs, and Outer Tie Rods using all OEM Toyota parts with the correct part numbers for my truck. I did the same thing counting the threads and using a paint pen to mark the jam nut to the inner tie rod. I was very meticulous reassembling everything and torquing all of the fasteners to spec, yet when I test drove it the toe was way out of whack and no matter what Ive tried so far it doesn't want to seem to hold my adjustments. Wheels are squealing while driving above 5 mph almost like the wheels are fighting each other. I did everything by the book...literally even what it says to do for Toe adjustment in the FSM. I used digital calipers to adjust the inner tie rods until they're exactly the same length, but still the same result.

 

Your new components are probably different than the old. Get your measurements to center front and back of the tire, close enough to drive, and then get an alignment. I did paint pen and measurements when I replaced my front end and it was different afterward. All OEM too. I guess I’m just saying don’t over think it.