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How does the axle come into play here? If the truck is not in 4X4 and the hubs are unlocked. Shouldn't the u-joint be still and the front wheels free wheeling? Sorry to question you Mike.
I also had the same issues described by the O.P. The steering box was sticking and then releasing. I would turn the wheel a little and get no reaction from the truck. I would turn it a little more and it would unstick and try to send me into the other lane of traffic. I had a couple of really close calls towing my trailer back from RRE 2012 on I-40.
My theory was crap from the pump found its way into the steering box I also had some hydra boost issues going on at the same time. I had flushed my system 1 time at 60k miles and the oil was really dark. My problems happened about 10k miles later.
I changed the pump first and it did not correct the problem. I ended up changing the steering box and Hydra-boost also. I also added a Magnafine power steering system filter.
The big nut that holds the pitman arm on the steering box. 1 5/16 is the size I believe. I don't know the torque. Mine was about 1 turn loose at least mabe two.
Was the nut visibly loose or did you check with a wrench or out a pry bar and wiggled it?
Yes, the shaft is supposed to freewheel, but when the shaft happens to turn into a position where the seized joint(s) is directly in line with the axis of the turn, is when you will have symptom(s).
How does the axle come into play here? If the truck is not in 4X4 and the hubs are unlocked. Shouldn't the u-joint be still and the front wheels free wheeling?
Frozen axle U-joints caused this symptom in my truck a couple years ago. Started exactly as you described. Eventually got so bad I almost wrecked the truck because the steering actually bound up.
Pull them out of the truck to check them. You are NOT looking for excessive play. You are looking for disintegrated needle bearings under the caps.
You may have something there, because today I checked the u-joints. The lelt side moved freely, but the right would bind. He also said that this winter his 4X4 didn't want to work/I checked front diff. and he was low about 1/2L. The outer seals look bad as well.
The one on the right side off completely. Left side I think is missing altogether.
Video of the from end.
Just throwing this out there. On my truck the shop that changed my steering box used a 32 spline box on my 36 spline pittman arm. It partially stripped the splines on the pittman arm. In one direction without the stripped splines it would turn normally. Turn the wheel the other way and there was six inches of movement before the output shaft found splines good enough to engage.
I found the problem by having my wife turn the wheel in both directions while I laid on the ground watching the pitman arm. Advance auto had no idea that there was two different spline counts on the output shaft. There parts system showed the same P/N for all Ford trucks of our model years.
I would check everything everyone else has mentioned, especially the axle u-joints being frozen.
The only other thing I can think is the steering box freeplay is adjusted too tight. This is probably not something that would happen on its own though, only if someone messed with the adjustment. I recently tightened mine a bit too much and had the exact issues you described until I backed it off a hair. If no one has touched it recently, its most likely not your issue.
Today i lifted the front of the truck and was looking at the right side locking hub. The **** was in the free position, same as the left side. I sprayed WD40, thinking maybe, just maybe. Then I started turning the wheel forward and back wards listening to (if any) noise that may be coming out the front right side axle/U-jount/hub then I heard a click. Looked around to the back side of the wheel and noticed that the u-joint was now free without binding as stated before.
Could this have been our problem from the start. I mean if the right side hub of the 4x4 was some how seized, would this have given me a shaky steering. I did test drive the truck and all seemed fine. Remember the issue would sometimes come and go before so I am a little wary that this was the culprit.
Any suggestions.
Have I fixed this (possibly $$$) problem?
Or could it still be something else that I should look at?