I. Question
We have a quartic in $v$ to be made a square,
$D^2 = 4(-6 - 2u + u^2)(2 - 2u + u^2) - 8(-2 - 4u + u^2)(2 - 2u + u^2)v - 16u(4 - 3u + u^2)v^2 - 4(4 - 12u + 4u^2 - 2u^3 + u^4)v^3 + (4 - 8u - 4u^3 + u^4)v^4$
If there is rational $(u,v)$ such that $D$ is also rational, then the quartic is birationally equivalent to an elliptic curve. And if we consider only $u$ of small height (numerator and denominator with absolute value less than $1000$), then only $16 $ $u$ are known.
Q: How do we find more $u$ of small height? (The context of this curve is given below.)
II. Background
Noam Elkies found the first counterexample to Euler's conjecture that $x^4+y^4+z^4 = 1$ has no rational point $xyz \neq0$. We provide a slightly different method that produces pairs of solutions. Let,
$$x^4+y^4+z^4 = 1\tag1$$ $$\frac{(x-y)^2-z^2-1}{x^2-xy+y^2+(x-y)}=u\tag2$$ $$\frac{(y-z)^2-x^2-1}{y^2-yz+z^2+(y-z)}=v\tag3$$ $$\frac{(z-x)^2-y^2-1}{z^2-zx+x^2+(z-x)}=w\tag4$$
where the $(u,v,w)$ have the simple relationship,
$$2(u+v+w)-uvw-4=0$$
Use the first three equations to solve for the three unknowns $(x,y,z)$ to get, \begin{align} x &= \frac{P_1\pm(u^2-2u+2)(v^2-2v)\sqrt{D^2}}{P_0+D^2}\\ y &= \frac{-(P_1+P_2+P_3)\pm 2(u+v-2)(u+v-uv)\sqrt{D^2}}{P_0+D^2 \quad}\\ z &= \frac{P_3\pm(v^2-2v+2)(u^2-2u)\sqrt{D^2}}{P_0+D^2} \end{align}
with $D$ as defined in the first section. The $P_k$ are,
\begin{align} P_0 &= (2 + u^2)(2 + v^2)(12 - 8u + 2u^2 - 8v + 2v^2 + u^2v^2)\\ P_1 &= (-4 + 4u + 2v - u^2v)(8u - 4u^2 + 4v - 8 u v + 2u^2v - 4v^2 + 2v^3 + u^2v^3)\\ P_2 &= 2(- 4 + 4u + 2v - u^2v)(4 - 2u - 4v + u v^2)(-u + v)\\ P_3 &= (4 - 2u - 4v + u v^2)(4u - 4u^2 + 2u^3 + 8v - 8 u v - 4v^2 + 2 u v^2 + u^3v^2)\end{align}
For example, let $u = -\frac{9}{20}$, then,
$$D^2 = \frac{-9724476 - 9928v + 6396480v^2 - 6677284v^3 + 1280881v^4}{20^4}$$
One solution is $v = -\frac{1041}{320}$, or $v = \frac{1000}{47}$. Using the positive and negative cases of $\pm \sqrt{D^2}$, either $v$ yields,
$$\left(\frac{414560}{422481}\right)^4 + \left(\frac{95800}{422481}\right)^4 + \left(\frac{217519}{422481}\right)^4 = 1$$
$$\left(\frac{632671960}{1679142729}\right)^4 + \left(\frac{1670617271}{1679142729}\right)^4 + \left(\frac{50237800}{1679142729}\right)^4 = 1$$
From this initial point $v$, one can then find infinitely more $v_k$.
III. The known $u$
The $16$ known "small" $u$ (and their initial $v_1$) are,
\begin{array}{|c|c|c|c|c|c|c|} \hline \text{#} & u & v & &\text{#} & u & v\\ \hline 1 & -\dfrac{9}{20} & \; -\dfrac{1041}{320} & & 9 & -\dfrac{41}{36} & -\dfrac{4061}{16308}\\ \hline 2 & -\dfrac{29}{12} & \;\dfrac{1865}{132} & & \color{blue}{10} & -\dfrac{5}{44} & \dfrac{57878913}{12642040}\\ \hline 3 & -\dfrac{93}{80} & -\dfrac{400}{37} & & \color{blue}{11} & +\dfrac{233}{60} & \;\dfrac{7584}{54605}\\ \hline \color{red}4 & -\dfrac{400}{37} & -\dfrac{93}{80} & & \color{blue}{12} & -\dfrac{56}{165} & -\dfrac{383021}{380940}\\ \hline 5 & -\dfrac{136}{133} & +\dfrac{201}{4} & & \color{blue}{13} & -\dfrac{125}{92} & -\dfrac{936}{5281}\\ \hline \color{red}6 & +\dfrac{201}{4} & -\dfrac{136}{133} & & 14 & -\dfrac{361}{540} & +\dfrac{1861}{240}\\ \hline 7 & -\dfrac{5}{8} & -\dfrac{477}{692} & & 15 & -\dfrac{817}{660} & -\dfrac{1581}{1520}\\ \hline \color{red}8 & -\dfrac{477}{692} & -\dfrac{5}{8} & & 16 & -\dfrac{865}{592} & -\dfrac{14177}{20156}\\ \hline \end{array}
Can you find more $u$ of small height that will yield new primitive solutions to $a^4+b^4+c^4 = d^4$ with $d<10^{27}$ different from the 30 known $d$? (Update: Now 93 $d$ as of Feb 21, 2024 in this table.)
Note 1: Since $(u,v_k)$ and $(v_k,u)$ both solve the quartic, then there are in fact infinitely many $u$ of increasingly large height. Likewise, the $w$ of $2(u + v + w) - u v w - 4 = 0$ also solves the quartic.
Note 2: The first ten (except the red ones) were considered by Tomita here and here. The blue ones were found by Andrew Bremner in this post. It may be that #10 has a smaller v. (Update: No smaller v. See this MO post.)
IV. Update
Several new $u$ found in the answers below can also yield small $d<10^{14}.\,$ S. Tomita found 6 while D. Fulea found 3 with Fulea's $u =\frac{553}{80}$ yielding $d\approx 5\times10^9$,
$$24743080^4 + 3971389576^4 + 4657804375^4 = 5179020201^4$$
the smallest known since 2008.
Solutions were found with $d<10^{26}.$
I. New u
$(u,v)=(\dfrac{1744}{495}, \dfrac{135}{1208})$ with rank $3$. Then $\pm \sqrt{D^2}$ gives the pair,
$$372623278887^4+435210480720^4+369168502640^4=521084370137^4$$ $$4408757988560^4+5819035124295^4+5611660306848^4=7082388012473^4$$
$(u,v)=(-\dfrac{3168}{1553}, -\dfrac{857}{3696})$ with $2 \leq$ rank $ \leq4$. $$19031674138785^4+25762744660064^4+2054845288320^4=27497822498977^4$$ $$2927198165920^4+613935345969^4+6310500741600^4=6382441853233^4$$
$(u,v)=(-\dfrac{1376}{705}, \dfrac{14337}{340})$ with rank $3$.
$$36295982895^4+29676864960^4+11262039896^4=39871595729^4$$ $$148739531603136^4+32467583677535^4+220093974949320^4=230791363907489^4$$
$$443873167360^4 +142485966505^4+ 544848079888^4=597385645737^4$$
$$468405247415^4+1657554153472^4+801719896720^4=1682315502153^4$$
$(u,v)=(\dfrac{2265}{184}, -\dfrac{68256}{135125})$ with rank $3.$ $$78558599440^4+814295112544^4+337210257575^4=820234293081^4$$ $$7745659501403353894384^4+2120589250533219579335^4+11684173258429439467360^4=12214291847502204701241^4$$
$(u,v)=(-\dfrac{1245}{5012}, \dfrac{248521}{62784})$ with rank $2.$
$$39110088360^4+49796687200^4+71826977313^4=76973733409^4$$
$$12209879806944320496330055^4+26621272474250391413865480^4+30730370351168229154149048^4=34497456764264994703368889^4$$
II. Old u with new v
$$34511786481280^4 + 56329979520665^4 + 26636493544576^4 = 58844817090201^4$$ $$1891988836723177605880960^4 + 985329200220584284726784^4 + 3003225858017812695181145^4 = 3122849928997768901912409^4$$
$$1724845107301282006322000^4+574585584668340612894713^4+1018986340666195845813760^4=1779979592349189232414713^4$$
$$8281143989708209432415360^4+1749772249172099623115896^4+6550300128305909879699935^4=8997319881974346759473697^4$$
$$69320669852667799672^4+38320435200564613600^4\\ +56375727168307546985^4=77107030404994920297^4$$
III. An elliptic curve example
For $(u,v)=(-\dfrac{125}{92}, -\dfrac{936}{5281}).$
$$V^2 = 2028135809U^4-10348419236U^3+15452504000U^2-19864419528U-2701875708$$ $$Y^2=X^3-X^2+9243195710310751148X -761969307339454319105751548$$
where,
$U = (4806380418543401982X-904918222778168849178608076600-160675940688120Y)/W$
$V = (-290502664258777889830361189336987740318300847654664Y+30351227342319833611479328476809250X^3-2575941095132966226374274732384734806159817640X^2-280542332655903002803396928758943793134265195041307240X-7890389152832211150695233323867214891900261612757200780457112240)/W^2$
$W = 906548763647395Y+161779100249526028403X-238333975114378921359218316974$