Steering changing every day… weird

Got an odd one, just replaced my steering rack that was leaking with a cardone steering rack (was a bit annoying to replace but not that bad) and swapped my suspension with kings. I got the new rack on and likely attached the steering knuckle coupler a few teeth to the left, I thought no big deal this can likely be centered during an alignment by adjusting the toe. Got the truck in the alignment shop and a few hours later got it back with the steering wheel centered.
I took the truck out for some light wheeling the next day and must have wheeled it a bit harder than I thought as my alignment was off and the steering wheel about 10 degrees to the left was straight driving for me. Again no big deal not the first time I’ve bumped my alignment out of spec but here’s where it gets weird. I get home park the truck, the next day I jump in and now the alignment is driving straight about 5 degrees to the right, the next day back to 10 degrees to the left. The next, back to right.
Anyone have any ideas as to what may be causing this? Outside of the wheeling on one day I’ve just been city driving (no I did not hit any potholes or curbs each day which would make it go back and forth)

 

With nothing else to go on, I suspect the installation of the steering rack is the root cause.

 

My personal rule:
"You always start first where the last guy worked." (even if was you)

Go back and check everything that was replaced or adjusted, more often than not you will find the problem.

 

It's either error on the rack install or the alignment left bolts loose.

I'd start with the rack.

 

Most likely one or both of your front cam bolts is shifting under load. Because they are round, they shift easily unless you torque the shit out of them. The front cams are directly under the steering rack, so any little shift translates into an equal shift in toe.

To complicate matters, the Cardone rack will probably fail in a month or two anyway... Reman racks don't seem to last on this platform.

 

Thanks that’s helpful! Saw a lot of recommendations with people throwing the cardone rack in so hopefully it will hold up lol. If it doesn’t any suggestions on a replacement?

 

^You can expect similar service life (6 years) with a new Toyota OEM rack. The Tundra rack conversion is more durable but more difficult to install (have to pull the diff, and possibly notch the frame to clear the steering shaft).

 

Is your truck also pulling differently when you let go of the steering wheel in these various states? If not then it sounds like the steering rack bushings are worn