Crossover Steering-Tying up the loose ends.
Correcting the Pitman Arm:
Last year I installed an ORD crossover steering setup which included their steering arm, drag link, and pitman arm. Here
One issue I had, even with the extended bump stops, was the tie rod end (TRE) at the pitman arm would drag over the top of the driver's side leaf spring when that spring was compressed (probably because of my suspension's fairly "short" 4" lift and flexible springs). Clearance to the engine crossmember seemed plentiful. I decided that I needed a pitman arm with less drop.
I looked around the shop and came up with a couple alternatives.
From top to bottom, stock '78 4wd, stock '88 2wd, ORD crossover arm.
Not pictured is a Skyjacker 4" drop arm which appeared to have just as much drop
as the ORD arm, but was a little shorter.
The '88 2wd arm (middle) looked like it might work. The only problem was the tapered TRE hole was too small (but the taper angle was correct).
Left to right, ORD arm, stock '88 2wd, stock '78 4wd.
As I recall the small end of the ORD arm measured .660", the '88 2wd was .620", and the '78 4wd was .640", but I'm not sure if I am remembering those correctly.
To open the tapered hole to the larger size, I bought an 1.5"/foot tapered reamer made by Xkut off of Ebay.
It worked great and quickly opened the hole up. I had to check the size often because the reamer worked so fast.
After installing the arm I had another issue. Even though clearance to the leaf spring was great, this arm moved the drag link much closer to the crossmember.
Full left lock. I think the clearnce will be acceptable, but I haven't had a chance to flex it and make sure.
Full right lock. The part of the drag link nearest the pitman arm was hitting the crossmember in this position even though most of the arm easily clears the crossmember.
So, using a die grinder with a cut-off wheel, I chewed off a small portion of the crossmember.
Both pictures at full right lock.
It clears great now. I have wheeled several trails since this modification, it has never contacted the leaf spring or the engine crossmember.
