Finished the Luke's Links mod today. Put Luke's Links on both tie rod ends and both ends of the drag link. Working steady, but slowly, it took me 4 hours and 50 minutes to remove the bars connecting the pitman arm to the tie rod ends at the tire, install all four Luke's Links, and reinstall the bars. On a scale of 1 to 10 (10 the hardest), I'd rate this a 4 if you have the tools. This isn't a difficult install just a bit tedious and the bars can be difficult to hold in position if you don't have a vice. According to the instructions, you can do the install using a vice, press or striking with a ball peen hammer. I found using the press is difficult if you don't have someone steadying the other end of the bar your working on. Using a vice it is much easier to get everything positioned. I ended up using both the press, the vice, and a hammer and it was relatively easy to get the tie rod stud removed from the bar.
Things to note when doing this install:
When grinding off the back side of the tie rod ends, I kept checking the spacing using the Luke's Link cap. As you grind the back of the tie rod ends, the instructions show a dashed line to indicate the outer edge of the plug. A couple of times, I didn't grind enough off, initially a line appeared on mine tie rod ends which I thought was the plug but it was actually the inside of the original ridge that circles the tie rod back surface. When I tried to get the stud out at the initial line it wouldn't budge. I found that as I ground the back side of the tie rod end down and approached the point where the Lukes Link Cap would slide on another line appeared. When this line appears around the entire tie rod end a sharp tap with the hammer will remove the stud. The key here is to constantly check as the back is evenly ground down until the Luke's Link Cap is just ready to slide on, just before you can slide on the cap you should see the plug line.
When initially setting up nylon bushing, large spring, and the urethane spring, you are to have 3/16 in showing above the back of the tie rod end. I cut a wood wedge at the point where it was 3/16 in thick and used that as a gauge. That way I could repeatedly get the same measurement distance.
I had to grind between 1/8 in and 1/4 in off the urethane spring. I ended up slipping the urethane spring onto a bolt and than putting the bolt into the vice. Since the urethane spring was tight on the bolt, I was able to grind the spring down fairly easily. NOTE: When grinding the urethane spring you will see a ridge appear that looks a lot like soft cheese, about the same consistency as RTV. DO NOT brush this off with you fingers as soon as you stop grinding. Just as the stuff looks like soft cheese, it is also HOT like hot/soft cheese and it also STICKS like hot/soft cheese
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The reinstallation of the bars was pretty easy but the tie rod ends didn't line up so I had to move the steering wheel back and forth (even though I didn't change any of the length adjustments). I actually got someone else to turn the steering wheel while I fit the tie rod studs into their holes. In retrospect, I put the tie rod stud in the pitman arm first and than had to move the steering wheel in get the tie rod studs in each wheel individually. I suspect it might have been easier to put the tie rod studs in the wheels first and then put the tie rod stud in the pitman arm. I finished by torquing the studs to 60 ft/lbs and then tightening the castle nuts enough to put the cotter pins back in.
Tools I used:
Socket set: metric and SAE, torque wrench, pipe wrench, pliers, pickle fork, side grinder, vice, 12 ton press, grease gun and a wood wedge.
Driving impression: Just took a short drive and I didn't notice a lot of improvement (but then, my steering was pretty tight to start with after the DSS and 3rd gen track bar
) prior to the install I had about 1 to 2 in play in the steering. It is really hard to tell, but I think the play in my steering wheel is less then 1 in. Overall, I'd make this mod again since I had a couple of loose tie rod ends anyhow.
Over the last two weeks, I have installed the 3rd Gen trackbar mod, the DSS steering stabilizer, and the Luke's Links. In my case, the 3rd Gen trackbar mod made the most difference to the steering system. The DSS had the next largest effect and the Luke's Links had the least effect. I suspect how much effect each will have on a particular truck will vary depending on what parts have the most wear. Bottom line is that I would not hesitate to install any of these upgrades as they all improved the steering of my truck.
Attention: TDR Forum Junkies 
Oo. 
. They gave me the dimensions for the washer and said I could get one at hardware store. 
