I have tried new tires and a balance and the vibration remains. The steering wheel doesn't shake or vibrate much and it's not in the brakes, but it DOES vibrate a little worse when I brake. It is most prevalent above 60 MPH, and gets really bad between 65-75.

Can anyone shed some light on this? It's driving me nuts.

Have you replaced your tie rods ever? Mine did the same thing at highway speeds for a while and I finally figured out I needed to replace my tie rods. Now there isn't any shaking at all and it wasn't too much to get 'em replaced

get an alignment. that will also tell you if you need anything new like the tie rods or ball joints.

Exactly how I found out that I needed to get new tire rods!

I have the same problem I just replaced the front sway bar links and bushings that wasn't it I think I need an alignment though, it may also by the steering bushings, but tie rods are next to check out. my truck kinda moves to the side when I'm on unlevel road on the freeway..

Nope. Never been replaced. That was my suspicion, as well as my dad's, but I wanted to see if anyone else had any insight. I'll be replacing them as soon as possible, then. I have new steering bushings, I've just not been able to get them installed yet.

Is it the outer or inner tie rod ends that need to be replaced? Or both?

I may need both inners and outers. The inners aren't visible, they're inside the boots of the steering rack. Do them at the same time as the rack bushings.

How hard are they to replace? I've got the main support bushing already replaced, but the other two smaller bushings I've yet to get to.

On a scale of 1-10, I'd say rack bushing are a 7. Mine were a pain. I used a c-clamp and a big socket (can't remember what size) to get the metal bushings in/out and it was still not easy. The TREs weren't bad, they went quick. Get an alignment afterwards if you do your TREs and/or upper or lower ball joints.

Oh trust me, I know the bushings are a pain. That's why the 2 on the end haven't been changed yet. I worked on them for two days and never got them out because I couldn't get the rack far enough back.

Do the ball joints need to be replaced at 160k or are they pretty good? I just want to knock out as much of this vibration as possible since this is my daily driver. I'm eventually going to lift it and put 285's on it, but not for a little while.

Tie rods are a very strong component of the steering system for obvious reasons so tie rods are unlikely to cause a vibration issue, but misalignment definitely is. The tie rods are replaced usually because they seize, or more obviously, when bent or broken (serious impact to cause this). If they are seized then a mechanic can't align, hence the need for replacement. Maybe it was just me, but it was sounding like the vibration issue was from the tie rods, which is unlikely. Another common vibration cause is a u-joint. That could explain why you feel a vibration with no signs of it in the steering wheel. Even warped rotors would generate vibration in the wheel. Good luck, chasing vibration issues is a lot like chasing ghosts

I have thought about the u-joint, but it mainly feels like it comes from the front end. I need to get an alignment since I got larger tires, but I hesitate to pay someone 70 bucks to do an alignment only to find out I need to replace tie-rod ends or some other suspension component that is related to alignment..

You're 4x4 so you could still have a u-joint issue in the front end. You can always check the tie rods yourself to see if you can turn them or if they look damaged at all. Oh, and find a place that offers lifetime alignments like Firestone. I've had some people on here recommend the same and I plan on following the advice

I took my 4runner in to get an alignment one day and they called me saying they started doing the alignment and noticed my tie rods were bad and said they couldn't do the alignment unless they replaced them so you can probably go to a shop and ask 'em to do one and well they won't be able to if you've got bad suspension components so they won't charge you. That's how I figured out what I needed done. Go to firestone and get there lifetime alignment! check out my thread on that:

Firestone Tire Alignment (GREAT DEAL!)