The local dealer did the Ball Joint Recall a few years ago and did not do an alignment, just slapped them in. Before I could get into the alignment Shop I use, the Cooper ATRs started to get a little noisy. I had the alignment done and as the Cooper ATRs wear, they look like a cutting tool for an old horizontal milling machine. I don't have any noticeable slop in the front end and the handling is great. I checked the ball joints with a dial indicator before the alignment and several months after and found no play.
I will give the front and rear suspension a check out tomorrow to see if there is anything not up to spec when I rotate them.
I am at ~93,000 miles.
What I do like about the Coopers is how they hold on ice and go through snow, they were quiet when new, but the noise is way too loud now.
Any ideas?

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle

Are yuo sure the alignment is right?
Also if the tires already had set up wear pattern they will continue to wear that way. So you may have ran them too long before getting an alignment

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MUDD'S MOTORSPORT'S We do IFS lift installs ,
03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited

They are aligned now and I will have the alignment checked again when I buy the replacements, that way they will get me in. I rotated them today and put the worst on the back. I checked all the ball joints, tire rod ends and bushings which are all good.
With the Cooper ATR 215 85 R16 I have heard of two others with KJ CRDs who had everything aligned right and they still wore weird and became noisy with more miles. I ave owned Cooper tires before on other vehicles and they were great, I just want a tire that works well on my CRD.

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle