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Tires were wearing badly on outside edge. First alignment said i needed a cam bolt kit so i put that on. Second alignment said the drivers side tie rod was adjusted all the way in, toe was "close enough". Tires wore some more. Third (free) alignment done by same shop said it was toe out, adjusted but said again the drivers side tie rod is all the way adjusted in. FOURTH ALIGNMENT I got fed up and paid big money for a dedicated alignment shop to do the work. Guy took his time, finally got the steering wheel straight, and said toe is perfect. He said he was able to adjust the tie rod so there were a few extra threads of adjustment. Great. Fast foreward a month later, i can clearly see my front tires toe out by just looking at them! Tie rod only has one thread of adjustment on the drivers side, and 7 or 8 on the passengers! WTF is this??
I have a standard pitman arm on my truck that has the 6" lift. Would this be the problem? Worn tie rods?? I need this thing to quit chewing through tires but have never seen this issue in my life..
I would think that you have some serious wear in your ball joints. Weird that one of your visits to a shop hasn't found that though. Is there any shimmy when you are driving? Possibly a bent rim or something odd like that? Lug nuts all tight and nothing on the hub holding the rim from sitting properly? Some lifted trucks require ball joints with an angle built into them to compensate for the spindle angle change. How long has the kit been on the truck, and what type of tires are you running?
Ball joints are all ok as far as i can tell. I replaced the passenger upper and drivers lower (i know i should do all 4 but ive been pressed for time lately). I figgure a ball joint issue would be more of a camber thing not toe. The lift was on when i bought it, i just dont know enough about lifts. Im running 35 bfg mud terrains.
Can you tell what type of lift it is? Brand wise? Are the lower control arms dropped with brackets and such? Is there any binding in the steering? Its a strange scenario for sure.
I cant tell exactly what brand of lift it has. What i can say is i believe i found the issue. Me and my neighbor slid underneath and were pretty sure whoever put the putman arm on put it a tooth or two off, causing it to have more slack on one end then the other.
check for clearance in the bushings inside the arm shaft case........ sometimes the bushing wear and the shaft wiggles and make it look like the arm is loose.
a bad ball joint can allow the knuckle to move in and out, which does effect the toe in more than you would think....... I normally put a floor jack under the A frame and lift the tire about 2 inches off the ground. Put a 4 ft 2 x 4 under the edge of the tire and pry up and down will looking at the upper and lower ball joints for Slop....... also grab the tire front and back and try to jerk it back and forth and see how much slop you have between the left and right sides.
And as for the ball joints the lower passenger has no slop even using a pry bar, but has the boot ripped so i need to replace that. Drivers side is new moog
Edit: wanted to add that i had my fiancee sit and wiggle the slop in the wheel, hooping id find a bad tie rod or something. Nothing moved, i guess all the slop is in the steering box. No pops turing the wheel when parked, but probably should swap out the tie rods anyway
when you were talking about the pitman arm, I was thinking of my slop I the idler arm bracket. the shaft turns on two bushings and I had a bushing wear out... slop appeared to be in the pitman / steering, but was really excess movement of the idler which is bolted to the frame............... generic drawing above..
there are so many different things that can "wear" that its hard to pin point a "normal failure point"... you got the right idea, crawl under, jack it up and twist, push, pry and see what is moving......... your toe in should not change over a short period of time... you would think a good align shop would pin point the problem, so I must not be readily visible ......... big tires and lift kit might be covering up or exaggerating a small problem.
there are bigger pitman arms for trucks with high lifts. Don't know that I helps the toe in, but it sure would make things fall into alignment better during assembly. Keeps the angles closer to factory spec I would guess. (below for reference only, not your truck).
lower control arm bushings?? To check ball joints I would jack it up under the lower control arm and try to rock it. You can also try a huge pair of channellock pliers with the wheels at full droop. See if you can find any wiggle. If the alignment is changing every time you put it on a rack then there's something loose. Even the wrong pitman arm for your lift wont give you different readings every time. Something is loose somewhere that it's changing.