I HAVE JUST FITTED NEW 16 INCH WHEELS AND TYRES TO MY 1990 HILUX 4X4 ...SINCE PUTTING THEM ON THE STEERING IS A BIT VAGUE AND WANTS TO WANDER A BIT... I HAVE HAD A CASTER KIT FITTED ALSO..THE BEARINGS HAVE BEEN REPACKED AND BALL JOINTS ARE STILL TIGHT ... I HAVE HAD THE STEERING ALIGNED AND THERE IS NO SLACK IN THE STEERING... THE STEERING DAMPER IS TESTED AND OK...DOES ANYONE HAVE ANY CLUES ???
Wandering is usually caused by toe-out. Did the aligner use front wheel drive specifications for this rear wheel drive truck? A front wheel drive toes in when the wheels are pulling the car, but the front wheels on your truck drag back to a toe-out position if steering parts are worn. Try pushing the fronts of the front wheels apart. They should still be at least a 16th of an inch closer in the front than in the rear of the tires.
Had the same problem a few times one with a Pajero and a few times with an isuzu trooper. My problem was I mostly drove a car but had a 4x4 for towing. The 4X4's really scared me I would'nt pass 40mph. Like yourself I tried everything and the only cure I could find was I did'nt drive anything else for a week then I had no problem but when I dont drive it for a while it still seem's wandery. I know rally cars have lowered suspentions to make them more stable so I think it is more to do with the high suspention and rear leaf spring's than a faulty part. Hope this help's. Cheers
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