Attention: TDR Forum Junkies 
I spent the big bucks for both the DSS steering box support and the adjustable 3rd Gen trackbar conversion, with bracket, for my '96.
The DSS was a very poor fit. The frame holes, even though slotted, would not allow for centering the bearing support under the steering sector. Worse yet, the bearing support was @ 1/4" too high and would not allow the bearing to be bolted onto it before bottoming against the extended pitman nut shoulder.
I had to cut the bearing support plate entirely off, mount the crossmember to the frame, then center the plate under the steering sector while also using some 3/8" steel plate to space it downward so the bearing saddle could bolt flat to it.
Sure, i could have tried to send the item back, but I ordered it long ago and was waiting for all my frontend parts before tearing into the truck. My time and opportunity to do these repairs and upgrades is very limited, so all the cutting, fitting, and welding was faster than waiting for another DSS, which might have the very same problems. Still, it took many hours; not the 'minutes' they say installation should take.
It now fits very well and is stronger than original. There is a slight problem with the stock '96 steering stabilizer on the y-style tierod/steering linkage hitting the DSS bearing saddle at full lock, despite having dropped the bearing support plate 3/8".
That is not a big concern since I seldom turn that tight and will soon have the T-style linkage and different style stabilzer shock and mount on the truck, too. I will make sure everything clears then.
The 3rd gen trackbar adapter plate, while thick and strong, is a poor fit to the contours of the Dodge frame. It leaves a large gap which allows the bracket to flex a great deal when turning the wheels.
I had to build an entirely new snowplow frame brace on the driver's side to accomodate the new trackbar adapter bracket. I left the bracket alone.
However, I can see no difference between allowing the bracket to continue to flex than allowing the trackbar bushings to be worn. It adds slop. And it will, IMO, cause the premature fatigue failure of the bracket and/or mounting bolts with possibly dangerous consequences.
So I see little choice but to bridge the gap between the frame and the bracket and weld it solidly to the frame. I don't plan to ever return to the 2nd gen junk trackbar setup, so that doesn't bother me.
What DOES bother me is the HUGE money they get for these items and the poor quality control that goes into building them.
This has been my experience. Your's may have been better. But I am not happy with the money spent, or the extra time and materials it took to make these items actually fit right and work right.
If it weren't for my extensive steel fabrication equipment and a good stock of steel, the installation would have been impossible for the DSS.
The development of these improvements was ingenious and much needed. For that I applaud the manufacturer. But if they wish to command such high prices, they should have much better quality control and fit.
The DSS was a very poor fit. The frame holes, even though slotted, would not allow for centering the bearing support under the steering sector. Worse yet, the bearing support was @ 1/4" too high and would not allow the bearing to be bolted onto it before bottoming against the extended pitman nut shoulder.
I had to cut the bearing support plate entirely off, mount the crossmember to the frame, then center the plate under the steering sector while also using some 3/8" steel plate to space it downward so the bearing saddle could bolt flat to it.
Sure, i could have tried to send the item back, but I ordered it long ago and was waiting for all my frontend parts before tearing into the truck. My time and opportunity to do these repairs and upgrades is very limited, so all the cutting, fitting, and welding was faster than waiting for another DSS, which might have the very same problems. Still, it took many hours; not the 'minutes' they say installation should take.
It now fits very well and is stronger than original. There is a slight problem with the stock '96 steering stabilizer on the y-style tierod/steering linkage hitting the DSS bearing saddle at full lock, despite having dropped the bearing support plate 3/8".
That is not a big concern since I seldom turn that tight and will soon have the T-style linkage and different style stabilzer shock and mount on the truck, too. I will make sure everything clears then.
The 3rd gen trackbar adapter plate, while thick and strong, is a poor fit to the contours of the Dodge frame. It leaves a large gap which allows the bracket to flex a great deal when turning the wheels.
I had to build an entirely new snowplow frame brace on the driver's side to accomodate the new trackbar adapter bracket. I left the bracket alone.
However, I can see no difference between allowing the bracket to continue to flex than allowing the trackbar bushings to be worn. It adds slop. And it will, IMO, cause the premature fatigue failure of the bracket and/or mounting bolts with possibly dangerous consequences.
So I see little choice but to bridge the gap between the frame and the bracket and weld it solidly to the frame. I don't plan to ever return to the 2nd gen junk trackbar setup, so that doesn't bother me.
What DOES bother me is the HUGE money they get for these items and the poor quality control that goes into building them.
This has been my experience. Your's may have been better. But I am not happy with the money spent, or the extra time and materials it took to make these items actually fit right and work right.
If it weren't for my extensive steel fabrication equipment and a good stock of steel, the installation would have been impossible for the DSS.
The development of these improvements was ingenious and much needed. For that I applaud the manufacturer. But if they wish to command such high prices, they should have much better quality control and fit.
