Unlimited_Fun

"Check your steering intermediate shaft " . . . roger that, although I'm not sure what constitutes a pass\fail inspection. This doesn't account for the sheer amount of leaking from the gear box though.

Also, last year I had Firestone do a front end alignment and they mangled the tie rod end adjusting sleeve, so I bought a new one had them use. This week while on the rack at another shop, they reached up and wiggle wiggle wiggle the tie rod and and said "that shouldn't be like that".

Ok fine, I presume that the sleeve needs to be re tightened if it isn't buggered somehow by driving with the slack in it. That might account for some of the knuckly sounds I've been chasing.

Unlimited_Fun

I suppose I can re clean the gear box, lube the intermediate shaft and seal again and listen\watch. I'm prepping for an trip to rough country in May, so I want to be ahead of the curve on things that really need to be corrected and replaced.

The new shaft is cheaper than a refurb gear box, and your suggestion is basically free.

Also, last year I had Firestone do a front end alignment and they mangled the tie rod end adjusting sleeve, so I bought a new one had them use. This week while on the rack at another shop, they reached up and wiggle wiggle wiggle the tie rod and and said "that shouldn't be like that".

Ok fine, I presume that the sleeve needs to be re tightened if it isn't buggered somehow by driving with the slack in it. That might account for some of the knuckly sounds I've been chasing.

drumnatural

I used 5th wheel grease. It took about a year of adding it every few months but the clunk is completely gone. I guess it took a lot of grease to work. More grease then I was comfortable adding at one time.

Blakspire

If you do decide to go with a gearbox, its incredibly straight forward. You will need a pitman arm puller, but that's as complex as it gets. Let me know if you decide to do it and i'll post up step by step how to get it done.