OK seriously though, it could simply have been that the actor wasn't available. Remember that if they have to write 'Joe Carey' into a scene and the actor can't make it, the scene has to be rewritten.
I doubt that Josh Clark was too busy. According to IMDB, between 1995 (his last episode in Season 1) and 2001 (his character's death), he appeared as minor characters in a few tv shows and B movies:
- "The Invisible Man".... General Grimmond (1 episode, 2000)
... aka I-Man (USA: second season title)
- Impetus (2000) TV episode .... General Grimmond - "Crusade".... Kendarr (1 episode, 1999)
- The Visitors from Down the Street (1999) TV episode .... Kendarr - The Sender (1998) .... Barry Stoop
- "Babylon 5" .... Kulomani (1 episode, 1998)
... aka B5 (USA: promotional abbreviation)
- Movements of Fire and Shadow (1998) TV episode .... Kulomani - "Millennium" .... Edward Petey (1 episode, 1997)
- Weeds (1997) TV episode .... Edward Petey - Dark Breed (1996) .... Rice
- The Sweeper (1996) .... Wax