Need help with 3/4 non-tapered Ball Joint holes

[Luke Dukem]

I need to replace the steering linkage in my 69 bronco. The ball joint holes in the steering knuckle and pitman arm are 3/4 diameter and not tapered. I purchased a steering linkage set from Wild horses but the tapered ball joints are too small for the non-tapered holes. I'm looking for a solution cause i'm not that familiar with this truck. https://www.wildhorses4x4.com/66-75-ford-bronco-3-way-adjustable-steering-linkage

 

[Yeller]

You need something Like this to repair the hole. This particular one requires drilling out to 1" and welding them in, but I have seen some that were split on down one side to be used without welding. Personally, I would go the weld in route, no way it can work loose over time. The other option is to purchase a heim joint steering system like this to use a 3/4 bolt rather than a tapered tie rod end

 

[Oldtimer]

Take a look at these tapered bushing sleeves, they may help.

Tapered Bushing Set for Dana 44 Knuckles | James Duff Inc.

We are now offering 3 different tapered bushing sleeve sets to fit a variety of applications. Read below for more information on choosing which works best for you. We machine our Dana 44 disc brake…

dufftuff.com

 

[Apogee]

Like Yeller pointed out, machined inserts or SRE joint steering solutions would be the two basic options. I just did a kit from Ruff Stuff for GM TRE's and it uses split sleeves in the steering arms on the knuckles, and then a non-split sleeve for the pitman arm, noting that that one must be welded since it presses in from the top and the TRE comes in from the bottom. FWIW, I machined all of the holes for a press-fit and then machined some spot-face counterbores top and bottom so that the installed height was correct and allowed for the installation of the cotter pins. You'll need to decide whether you're going to install the tie rod over or under the knuckles either way.

 

[Luke Dukem]

The tapered bushing set looks like a good solution since I don't need to buy another steering linkage set and could get a stock pitman arm. I'll give them a call and see what they say.
Thanks for the info

 

[Johnnyb]

You are already a long way to heim or TRO with 3/4 already drilled, if you are going to go crawlin', look at this: https://dufftuff.com/product/dual-s...stem-1966-77-bronco-config/#heim-steer-system

 

[Luke Dukem]

I won't be crawling, just light beach use. The truck previously had one of these upgraded linkages but not a very good one. It was causing a lot of play in the steering wheel and it was too old and corroded to salvage.