This is an older post of mine on P4x4, but it kind of addresses the issue here.
I do not have a single bushing on my suspension, anywhere (well, with the exception of the shocks). This is not death, it's not instant catastrophe, and I rather like the way it rides and performs. Lowers run 2.5" Johnny Joints on both ends, uppers run 5/8 x 3/4 heims on both ends, panhard in front has heims on both ends. I can guarantee that I'll never run bushings on any future wheeling rigs I build. There are many more factors that contribute to undesirable NVH levels than running not bushings.
That being said - I would also absolutely NOT run all solid joints on a radius arm setup.
It's a matter of constraint, when it comes down to it. The goal of any suspension is to constrain the axle to a certain range of motion, which for (offroad use) ideally is:
- free vertical travel (within limits of other suspension components)
- free warp travel (articulation, again within limits of other components)
- zero lateral travel (panhard arc excluded)
- zero longitudinal travel (wheel recession excluded)
- zero torque twist (axle wrap)
Put more simply, you want the axle to move up and down, and you want it to flex. Anything else is not a good thing.
The 'binding' that people talk about is an effect of having the suspension "over-constrain" the axle. This happens when the links and/or geometry are fighting each other to maintain the axle in a certain position. A well-designed suspension (for offroad use, anyway) minimizes this from happening.
Case in point: look at a 3-link with panhard. Each link does its job in isolation. The three links that are roughly parallel do nothing to fight the panhard for lateral control. The single upper link is the only thing that controls torque reaction and pinion/caster angle. The two lower links keep the axle located longitudinally under the vehicle. This is what I've got, and even with rigid joints all around, there is NO binding anywhere in the range of usable travel. To get to the point where the joints run out of misalignment, I'm well beyond any possible driveshaft angle or usable travel.
If you look at the factory XJ suspension, it has a certain amount of 'overconstraint' designed into it. The slight triangulation in the upper and lower control arms resists lateral movement, but the panhard forces it through travel. Likewise during flex, the control arms on the right side are trying to maintain a different pinion angle than the control arms on the left side, and the difference is made up through distortion in the bushings (radius arms have this same issue). The big thing here is that the type of distortion in the bushings is not something that a heim or johnny joint can handle. Think of all the ways you can "squish" a bushing, compared to the ways a solid joint can move, and you'll see what I mean. The motion needed to compensate for that binding isn't entirely within the range of motion of a flex joint.
These reasons are why a 3-link with panhard doesn't bind, but the factory 4-link w/panhard does. Or why a traditional radius arm setup binds, but a wristed setup doesn't. By removing that one link or wristing an arm, you're removing that bit of overconstraint, and giving more free motion to the suspension.
So why do things come that way from the factory? That bind that radius arms experience has another effect - it reduces sway. If you think about it, body roll is no different than the axle articulating...it's just a matter of which thing remains stationary, and which thing moves. The Ford radius arm setup and the Jeep 4-link w/panhard are both very stable setups, that are great for going down the road and still offer a reasonable amount of flex before the bushings start to limit it. Neither Jeep nor Ford set out to create vehicles with monster suspension travel; they had to make compromises in order to satisfy the larger market, which is the street-driving population. The aftermarket then gets to address this with wristed Ford arms (think Cage or James Duff), or setups with different geometry (think RockKrawler 3-link for the XJ), that move that compromise away from road manners in favor of offroad ability. Keep in mind that what we consider 'acceptable' or 'pretty good' is much different than the ride quality & performance engineers at DCX or Ford.
So what's the point here? When I had radius arms on my XJ, I used factory bushings on the axle, with a Johnny Joint on the frame side. It was simple, cheap, and got the job done. Would Johnny Joints on both sides have helped anything? I don't think so. It flexed to the limits of the other components, and I didn't risk ripping control arm mounts off the axle from binding. After I got rid of that setup for the 3-link I've got now, I switched to rigid joints all around, because I wanted the best axle control possible, and didn't have to worry anymore about needing bushing deflection to account for binding.