Not sure about the new stuff ie 1996, but all the tapers are the same in all of the old trucks, Ford, Chevy, Dodge, Jeep. It is 1.5 inches taper per foot. The only difference between the makes is how deep they ream the hole.

 

I'm all sorts of confused. Do all the rod ends fit in the holes fine?

Before I make myself sound like an idoit trying to explain what I think is the issue and why I'm just gonna suggest taking out the drop pitman arm. haha easier that way. Could that help your clearence issue? It doesnt seem nesessary for you have one in there anyway.

 

The tapers may be the same but the diameter of the tie rod ends on the 78 f-150 is definitly bigger than the drag link joints and tie rod ends of the 96 stuff. The 96 tie rod ends go way to far through the knuckles.

 

no its in there...

 

So what's wrong with using the 78 tie rod and 96 drag link combo? The clearence is not enough between the two on the pitman arm side when turning, correct? Try a stock pitman arm, you hardly have any lift and dont have bad steering angles so you dont need a drop pitman arm anyhow. Or you could buy some new 4 inch springs.

 

Here is a drawing of what I need (the top one) with the bigger around ball joints. I am kinda likeing the idea of drilling and putting the inserts into the knuckles for the newer style except they are not as big around as the 78's