1994 knuckle problems - Ford Powerstroke Diesel Forum
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  #1  
Old 06-02-2013, 12:59 PM
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1994 knuckle problems

My passenger side knuckle wore out the hole where the tie rod bolts through so after I finally found a new (used) knuckle I bought all new tie rods.

even now with a new knuckle and tie rod when I tighten the castle nut the tie rod pulls so far up into the knuckle that its crushing the boot and ripping it. My driver side and perfect.

what is the deal with the passenger side? anyone else see this problem?

before long enough my tie rod will wear out again wallowing out my knuckle and my problems will start all over again.
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  #2  
Old 06-05-2013, 05:26 PM
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here is the knuckle
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1994 knuckle problems-2013-06-05-18.29.24.jpg  
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Old 06-05-2013, 08:23 PM
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Hard to tell what's going on in that tiny pic. Are you sure you didn't get a bad tierod end? I would pull it off and compare both sides and the knuckles to see what is worn.
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Old 06-06-2013, 03:34 PM
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if you click on the picture it will get bigger...

the tie rod is an xrf. my old tie rod end was fitting the same way. I thought I heard of the old knuckle with the slide calipers having problems with the passenger side knuckle hole that the tie rod bolts to.
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Old 06-06-2013, 04:24 PM
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Sounds like the best option is to install an insert. Not a cheap one, though.

The one's Blaine did on my knuckle flip are BEEF. He takes 7/8 thick wall chromoly and reams that to fit. Then drills out the knuckle so it has an interference fit, presses it in, then tigs it. Not going anywhere.

Interesting note, when you tig weld the insert, it pulls so much carbon into it and heat treats it on cool down, it becomes VERY hard. So hard, you can't use the reamer to fix any spatter if you get it in there.

Edit: It's not cheap, and you'd have to mail it to him, but I can send you his contact info if you like.

Last edited by Gaius; 06-06-2013 at 04:29 PM.
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Old 06-06-2013, 08:53 PM
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Your pic is only 320x240 when clicked on, that's 162nd the size of the screens I am sitting in front of which leave a lot to be desired. I haven't heard of the old knuckle having this issue, and it's what I run on my 95. If the knuckle is worn to the point it has a indentation then sleeving it would be a option and would allow for a heavier duty joint if you wanted to upgrade.
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Old 06-07-2013, 04:28 PM
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I was thinking of sleeving my old knuckle but couldn't find anyone that would do it around here. So I just found a used knuckle that had the correct inner dimensions (meaning it wasn't worn out)

has anyone used the xrf tie rods? Im wondering if they gave me a wrong part number?
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Old 06-07-2013, 04:43 PM
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Be easy to check, pop the other side out and mic the u-joint versus knuckle taper on both sides.
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Old 06-08-2013, 01:20 PM
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I did that, same size. so its got to be the tie rod
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Old 06-09-2013, 09:47 PM
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Did you mic the tie rod taper itself? Something's wierd...
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