Edit: FIXED! - Inter. steer shaft installed - still clunking

At my wits end, but as a hardheaded SOB I can't let it ride

2015 pre, dbl cab, 4cyl, 2wd

Recently installed were new oem lca's, tie rods, steering rack, jba uppers, ome 885s on lowest setting with bilstein 5100 all around (1/4" tophat spacer on driver side)

Installed the intermediate shaft to try and address the steering column clunk/rattle predominantly happening over washboard (which i drive daily)

Installed it and went on a shakedown - immediately came back and made sure everything was tight/tq'd to spec on literally everything suspension wise and steering shaft. All tight, no play on anything after yanking on everything

Bushings are still good on the rack and sway bar. Wheels tight. Any and everything i could muster

Body mounts? Frame? 1/4" top hat spacer?
What'd be yalls next place to look? Im tapped, been googlin' like a mf last 2 days

While the steering does feel tighter now the light steering column rattle and clunk is still there - seemingly always on front/driver side - almost feels like it's in the steering wheel

 

Check the driver side front fender is bolted on tight

 

Pretty sure it's snug, but anythings worth a shot at this juncture

 

Mine wasn’t. Place your hand on the fender above the wheel opening and push forward and back.

 

Wow, ok then I'm game. Bout to bust open the tool box then. I'll wait til after dinner and save the glares from the missus in the kitchen rn

 

14mm, I think. Just snug them.

 

OP, was the rack you installed OEM?

You might also want to check the adjustment on the rack guide bushing. That was a major source of my clunk. Also putting a slight preload on the shaft entering the yoke coupling of the intermediate shaft eliminated all remaining annoyance.

 

So I got up under the yoter this morning and tried this fellas approach...




To my absolute shock... it worked. Feels like a different truck now. The slip ring peice was too high in the column as denoted ^^

Got a buddy to hold a big flathead screwdriver in this part...



Which shoves the upper IM shaft down a scosh.

Absolutely amazed. Hopefully this will be a testament to attemp this if you've got the same issue


Halle-******-lujah