Stock 1997 expedition 4x4 5.4 v8 w/ torsion bars

I changed my pitman arm recently and now my tie rod is hitting the frame on passenger side. Not sure if tie rod is bad and hyper articulating or if its something else. Driver side is fine with an inch or 2 of clearance

 

Suppose we start with few questions.
Is the new pitman arm exactly the same as the one you removed?
The sector shaft coming out of the steering box has a scribe mark on it that is usually lined up with the scribe mark on the pitman arm, did you line them up?
Of course the next question is why was the pitman arm replaced?


I hope you and I are talking about the same part !! Pitman arm comes off the steering box.

 

I forgot to check that when i replaced it. I did reset it by counting the turns in either direction, so it spins equally in either direction. The part is identical but im guessing the splines are differen because it is not aligning where the old one did. The new one offsets the wheel a good 40°. I also have a little play in the idler arm, not sure if thay is what causing the tie rod to rise up and hit the frame either

Edit* pitman arm was replaced because of slack in the old one.

 

Ahhh, just what I suspected

I believe what you are referring to is the "Drag Link".
The drag link connects to the pitman arm and the other end connects to the tie rod.
If you still have the old parts, what you can do is to measure from the center of one to the center of the other end of the threaded posts , then adjust the length of the replacement to the exact length.
Now if we are still not talking about the same parts , and you do have an idler arm which I don't think is on your vehicle, I could be wrong, a badly worn idler would give all kinds of steering wander and excessive movement trying to keep the vehicle in a straight line down the road. I won't be able to offer any addl help since I will be going for some medical procedure and don't know if I will be able to type or see after it is done. I know our Super Moderator reads these posts and hope he will continue if you need addl assistance, Thanks Hayapower.

 

Yes i have an idler arm for sure, it does have a little play in it. Where the drag link and tie rod connect, that point sits right below the frame and they articulate up on right turns and rub the frame making a horrible sound.