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My truck has a lot of free play in the steering. Recently it began to pop when you turn the wheel but only within the freeplay. I climbed underneath it and it is popping right where the pitman arm and steering gears meet. So I am going to replace the steering gears, pitman arm (when I find one), and the draglink (when it was on the lift you could twist it). Am I going to have to get the front end re-aligned I'm not replacing the tierods, adjusting sleeve etc. What else, if anything, am I going to have to replace? How would you recommed I remove and install these parts? It is 2wd with p/s if this changes anything. Also it is popping in the steering column. If you pull on the wheel and then turn it the only popping you here is at the pitman arm under the truck. Any ideas?
Without seeing it for myself it is hard to diagnos your problem. What you will need is a pickle fork, (special tool to remove the drag link), you will also need a pitman arm puller, but I don't believe there is any reason to change the pitman arm, it is one solid piece of cast metal with no moving joint's.
Steering gears?? You must be pretty experienced with power steering gear boxes? I myself won't attempt to change or open up a gear box.
Does the popping feel or sound like it is from the gear box?
How much play is in the ball joint's of the drag link?
You should have some play but not excessive. That could be where the popping is coming from. yes you should have it aligned when done.
The popping is in the steering gears and I plan on replacing the gearbox and gears. (I don't think I could change just the gear I'm not that good!) The play in the draglink is a little excessive to the point when I pay in the field you can here it pop at the joints.
I had a similar 'popping' noise on mine that turned out to be a torn rag joint, located between the steering gear box and the steering column.
Have someone look at the joint while you turn the steering wheel. If it's bad, they will see it twist just as you hear it and feel it in the steering wheel.
Hope that helps.
There's been no mention of the king pins, spindles, castle nut, wheel bearings, front brakes for that matter, while you're checking/evaluating things might as well check lug nuts too, wouldn't be the first time a mystery was solved there.
Sorry to tell you I agree with one of the posts above, if any of the front end steering/suspension parts are wearing out, it's a pretty good bet the other parts are not up to par either. Why not rebuild front end, it really isn't that many different parts.
Pitman arm is considered a non-wear item isn't it.
Steering gear box. I thought I had wear/play in a 25 year old unit, tracked down a rebuild kit (not much to it) and rebuilt the box. Eat your Wheaties, that sucker is heavy. Didn't make a bit of difference.
Changed it out with a reman unit, made the slightest bit of difference.
So I'm suggesting you save it for last, cause it may be just fine.