I quit responding as this thread progressed, mainly because I was afraid that the Thuren alignment specs direction wasn't going to fix the problem, even though many times it does.
Solid axle suspension and steering components (especially T-type steering) are pretty basic. I think there is something simple that is wrong with this truck and it has been overlooked.
@KPotter44 , we need more concise information from you, along with a timeline of occurrence. In your first post you mentioned replacing upper and lower ball joints on the left side at 180,000 miles. Usually, ball joint replacements are done on both sides at the same time because they have equal time over lots of miles. Why did you just replace the driver side ball joints? In subsequent posts you mentioned the steering problem seemed to happening when you got new tires. In another following post you mentioned that those tires had been on the truck for about three years. So, has the steering problem been occurring for three years?
In Post#12 you mentioned disconnecting the drag link and freely rotating the passenger side wheel assembly left to right. Why didn't you do the same test for the left side, even though ball joints were new? It doesn't really matter whether the ball joints are old or new; it matters to know whether or not they are binding.
Alignment shops, like any repair shop, are always concerned about how long it takes to diagnose a problem because time is money. It sounds like you are getting canned procedures and responses to your request to solve this problem. I would try finding a shop where the guy says, "Well, let's take your truck for a test drive, so I can understand what you are talking about." Did any one of those shops test drive your truck before and after a repair, or alignment? You shouldn't be finding out that the problem wasn't fixed when you are driving home.
Which leads me to one of the objectives of this forum. Most of the people that use this forum are people who are working on their trucks and learning more about their trucks from hands-on repairs and maintenance. I think your quickest and least expensive way to solve your poor steering performance is to personally get involved in the diagnosis in a hands-on manner. I believe you mentioned that you have been a mechanic for years, but didn't know too much about alignment. The TDR is a great resource for that and I am sure there will be people willing to explain how to check each steering and suspension component under a load to rule them out one at a time.
Maybe you aren't able to do the work yourself and if so, there is no need to explain.
- John