2nd Gen Non-Engine/Transmission New twist on track bar problems?

[Dane]

I've been enjoying great steering response and tracking since upgrading to DT Track bar and Borgeson steering shaft approx 4 years ago. In the last 3 months however, I've been getting a "clunk" and a bit of wander on the road. I feel the wander as a over center "catch" when freeway driving. After watching parts move under the truck with the Wifey turning the wheel back and forth, I saw the problem was the track bar at the frame end shifting. So, I figured it was time for the DT rebuild kit, so I installed it. Steering was good for a few hundred miles and then the clunk came back.



While investigating today, I discovered I did not need the rebuild kit, the track bar was fine. The problem is the bolt holes on the frame bracket that holds the track bar have somehow enlarged. There is like 3/16" play side to side with the bolt through the frame bracket. The heim joint end has about 1/16" play between the bracket and the bolt.



Anyone else seen this problem? I'm thinking of welding some plates with new holes to the existing brackets. You can't really get to the actual frame bracket holes to weld and re drill.



Can I drill and then weld hardened steel to the mild steel crossmember bracket? Do I need a special drill bit for hardened steel?

 

[JimKing]

Seems to common with this bar. I am probably going to blasted here, but I had mine welded to the frame. The welder used a TIG, as it is supposedly will not cause frame cracking. Had mine welded at 40 K gonna turn 100K soon, no problems. .

 

[Cummins Thunder]

What are the risks of welding on a frame?? Not including the 3G trucks...



I welded (MIG) on a 95 Chevy not too long ago, I was very hesitant to do it but had little choice... .