Sas steering

Got the trail gear sas steering kit for my 97 taco, and the knuckles are both splined at one end and the other ends fit the two different shaft sizes. My problem is both splined ends of the knuckles are bigger than the steering shaft under the dash. Has anyone else done the kit, and the kit gives the option of 95 or 96-2004 I got the 96-04 and the instructions only reference the 95.5 taco to drill the steering column shaft and use set screw. Wondering if the later kit demands the same? Why would the end be splined if it’s bigger than the shaft diameter?

 

1" D with the spline go to the steering box. The 1/2" D with the spline attached to the factory steering shaft in the cab.

 

The D side of the knuckles are obvious, but is the splined end of knuckle to steering shaft supposed to be bigger than the shaft? Just wondering why the knuckle is splined if it serves no purpose. I emailed low range and they said all parts are correct.

 

So you're saying the splines on the u-joint (not knuckle) is bigger than the spline on the steering shaft from inside the cab? They fit on a couple tacomas I help assembled from 98, 00, 02, 04 and 3rd gen 4runner.

Maybe take some pictures so I can see what's occurring?

 

That’s correct

 

WTF.... that's weird

Only thing I can think of is your steering column got changed?

 

I bought the truck used from a dealer in about 2002 and it’s been in the family since. I’m just wondering if anyone else has the same issue or did they really send me the wrong part. I could drill a hole in the steering column shaft and use the set screw, but I’d rather have a tight fit on the spline. I sent another email tonight hopefully get more info Monday

 

I did this a couple months ago (I got Borgeson, not Trail Gear) and my 3rd gen 4runner column looks like this, went together no problem. I think your column got changed at some point.

 

After measuring the steering shaft looks like I need a 1/2” DD x 9/16” 26 spline u-joint. Google turned up zero results. Might have to find a different steering column with the proper shaft size.

 

Trail gear shows that there are separate PN options between the 1995.5 and 95-04

https://trail-gear.com/tacoma-steering-u-joint-with-hardware.html

 

This here. Had the same issue with my truck. TG kept sending the wrong one since there are different sizes depending on the year. Id contact them and tell them about the situation.