Brad-
I had this issue on my TR4, and am also configured pretty similarly to you as
I use the TR6 lower coupling and I've changed over to a relay setup. In my
case I tracked down the grounding issue to the lower shaft itself. Even
though the upper rubber coupling had the grounding wire, I was losing ground
right at the splined joint on the lower shaft - evidently corrosion builds up
over time. I solved it temporarily (now going on 2 years), by wrapping a 12
gauge grounding wire along the lower shaft to get a good ground all the way
through the column. At that point, no problem. If I were you I would also
have a grounding strap from the steering rack to the frame even though you are
using solid mounts. And no, I don't have a separate ground wire for that
lower coupling, it seems to ground just fine there.
Randy
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