I need some clarification.

Did you pull the pitman arm off, and visually inspect the sector shaft?

 

Yes sir looked like new! So i put it back on and torqued down.

 

It seems like you measured your track bar (or was it drag link). Track bar issue is my next suspect, even though you said the axle was centered. Wouldn't need to be off center much to turn your wheel 90 degrees. I'm ignoring the ESP light not being on, trying not to over think it and focus on the fundamentals.

I took some hard point measurements so you can measure your frame side track bar bracket, and axle side track bar bracket, to see if they've bent themselves out of whack.

First two pics for frame side bracket. Beginning measuring point is the opposite frame rail, just behind the frame seam. There is a bump in the metal. Center of that bump is the start point. From there to the center of the frame side track bolt was 31 1/2"

Second two pics from the axle side track bar mount. Start point for that measurement is the middle of the track bar bolt. Measuring to the lowers diff cover bolt on the passenger side. 21 7/16". This second measurement is a bit eyeballed, so it's not that reliable. I'd say it's accurate to within 1/8" either way. I doubt your using the stock track bar bracket, but just in case.

http://www.flickr.com/photos/72867051@N00/12393461385/
http://www.flickr.com/photos/72867051@N00/12393623543/
http://www.flickr.com/photos/72867051@N00/12393931834/
http://www.flickr.com/photos/72867051@N00/12393636633/
My main suspect here would be the stock axle side track bar bracket. Stock or aftermarket. Might have bent the stock bracket the aftermarket one bolts to (assuming yours is a bolt on)

 

Just measured for the hell of it. Damn near EXACT same measurements. My tire to frame is 5" exactly on both sides as it always was. I have a synergy bracket for my trackbar and a 1.5 x 1/4 dom trackbar. Neither of these budged....

 

Hmm. The only place my mind has left to go is into absurd territory. Like bent knuckle absurd. Bent pitman arm absurd. Or back inside the steering box.

Sector shaft. Check
Drag link. Check
Bracketry. Check
Track bar. Check
Heims or bent Heim bolts? (You don't use tie rods, is that right?)

 

I took one more pic to compare to yours. Wheels dead ahead, looks like your pitman arm is more off to the drivers side than mine.


http://www.flickr.com/photos/72867051@N00/12394678834/

 

I thought maybe bolts to but they all came out easy and looked straight. Heims are good also. I may take i in to get the alignment printout to Check knuckles. Even with the wheel where its at i get the same turn distance to the left and right.

 

hate to say it but it sounds like the gear skipped. Id adjust everything and get the wheel as close to centered as possible and just wait to see if it happens again. I don't understand why it hasnt messed with the abs esc systems at all though. Its a very strange collection of symptoms

 

So from wheels dead ahead, you get the same steering wheel turns to the left and to the right, like 1.5 left and 1.5 right? Or do you only get the same turns from the steering wheel dead ahead?

 

This sound unlikely to a high degree. I don't know how you skip a worm drive without breaking it. Unless the adjuster was super loose, but you'd have sloppy steering.