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The alignment/lift kit on my '95 F150 has been giving me fits since I bought it last July. Finally found a shop who seems to know what they're doing. It appears that the previous owner messed up when he installed the lift kit. It appears he installed axle drop brackets for a 6" lift and springs for a 4" lift. So, I ordered new 4" drop brackets (I like the height it's at now) with the extra brace that connects the two sides of the crossmember together. That, in addition to welding the crack in the crossmember and the loose crossmember rivets, should finally allow me to get the front end straightened up. It should also stop the creaking/groaning/popping sound when turning the wheels. Then I can get new tires without wearing them out so fast. Oh yeah, then I can think about replacing the leaky radiator. Maybe after that I'll look into fixing the oil pan gasket that's starting to leak a little. Oh well, good thing I like my truck.
I had some alignment troubles also with my '88 Ford F-150 4x4. After installing a 2 1/2" suspension lift in the front and replacing the stock '88 blocks with '77 factory blocks in the rear, adding a dropped pitman arm to help out with tie rod angles, and 15x10's and 32x11.50's, I developed a crack in the crossmember near the steering box and also a crack in the frame rail running toward the steering box. After several welding attempts, including adding a strap running from the crossmember to the bottom of the frame, I have been crack-free for going on two years now. However, alignment is still a sore spot. I have always been pleased with the tire wear, but after picking up the truck from the alignment shop, where the steering wheel is straight, I will eventually have to turn the steering wheel about a quarter of a turn to keep the truck going straight, until the next time I get it aligned, where the wheel is straightened again. This last time, I sprayed every adjustment I could find blue, so I could monitor any movements. What's causing this problem?
That's strange. Usually the thing that affects the steering wheel is the adjustment sleeves on the tie rods. Does it always turn the same way? Does your truck actually pull to one side and you have to steer against it to go straight, or does it drive straight but the wheel is just off? I had a problem with my '85 Bronco for years that even though it was lined up right I would have turn the wheel to the left some to keep it straight. It didn't feel like I was putting any real pressure on it until I had to tow it home one night after my starter died. It was all I could do to muscle the wheel to keep it straight without the power steering working. The thing that finally fixed my problem was getting rid of the BFG A/T's and putting on a set of Michelin LTX M/S's. Drove straight as an arrow after that. After that, my Dad told me he had the same problem with both his '85 and '88 Broncos with BFG AT's.
I always wind up having to turn the steering wheel about a quarter of a turn to the left. It usually ends up pulling to the right. Similar deal with yours, though. I don't feel I'm putting alot of pressure on it, either. Also, I am running 32x11.50 BFG A/T's - always have because they wear good for me and are reasonably priced. However, I may try a set of Michelin's next time.