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Weak idler arm repairs

BUDMAN

SM 2003
Full Member
Joined
Jun 14, 2002
Messages
1,948
Location
Katy, TX
Big tires and weak idler arms, compliments of GM, are not a good mix.  Awhile back, I snapped the bracket off the frame for the idler arm.  I know when it happened, and it wasn't mall-crawling.  Anyway, the bracket was welded back to the frame, and all was well.  That was short lived.

Apparently the damage was already done to the idler pivot assembly, and over time, the bearings/bushings slowly gave up.  The result is an arc pattern the idler arm moves now, instead of a straight line, and serious creaking noise, even worse than when I snapped the bracket.

The search was on for replacement parts and/or upgrades.  Not too pleased with the pricing, but it's workable.  Highly recommended is the Henderson's Supersteer SS175 idler arm support assembly, which comes in around $185 plus shipping.  http://hendersonslineup.dreamhoster...upersteer-idler-arm-support-assembly-–-ss175/  This would replace the blown up factory part that's ruined, but still doesn't address the frame brackets weakness.

Browsing some more, Cognito has come up with a single plate gusset to weld the bracket to the frame, giving much needed support.  I think most would be surprised if they saw how much that piece flexes with big tires.  Their kit looks like it uses Henderson's support assembly, but I haven't confirmed it.  As a kit, it comes out to $200.  http://cognitomotorsports.com/store/page28.html

There's not much of a difference between the prices, and the gusset would be pretty easy to fabricate, as well as modifying it even more to address both sides of the mounting point on the frame.  I have plenty of scrap 3/8 plate that would do the job, just need to make a template and cut it out.

One thing I hear regularly is the pitman and idler arms needing to be replaced, but these appear to be in good shape.  I may find out differently once they're removed, at least the idler arm.  Anyone have any dealings with these parts from Henderson's or Cognito?
 
From the lack of responses it looks like you may be forging the way into new territory here.  I for one am every interested in what you choose and how it performs because now that the majority of my steering linkage has been replaced with beefier parts, the stock idler pivot assembly is on my mind constantly...I'd rather upgrade before it fails.  Keep us "posted".
 
I too just went through this, I had a new bracket fabricated and then welded to the frame.  Whiplash, the maker of my lift kit, has also addressed this problem with an easy way to brace the bracket using 2 inch square steel tubing.  If anyone is interested they will email you pics and explain it.  I also have the pics from my problem.  The fix is good, the shop I chose to do it wasn't.  IF in Mobile, AL do not use Truckin' Up.  They welding it first with aluminum.........It didn't hold for 2 miles of course.  Anyone with a lifted av may want to look at this, my bracket moved and crushed the transmission lines.  They had to be replaced. Right now the bracket is welded to the frame I haven't had time to weld in the braces that Whiplash recommended.  That will be done real soon though.  I will also have to look at the henderson kit.
 
I have not has experience with idler/ pitmans on the AV yet...(still waiting for my truck) but I can tell you over on the HUMMER boards many of us have replaced theirs using the Cognito setup and has worked very well.  THey seem to build a quality product... esp. that you need to replace them one a year if you take the truck off road. 
 
After looking at it, I like Hendersons part but I like the brace that Whiplash recommends.  It would be a little stronger.  The difference in the Cognito kit and the Henderson Kit is just the little piece of flat steel to brace with in the Cognito kit.  I really like the Henderson part though, good find, I am going to get one ordered....
The shop tried a bracket something like the Cognito the second time, of course they didnt fab it right and it didnt last but about 5 miles and they only welded two sides of the bracket to the frame. anyway it's a long story about how bad this shop is.. I think the third time they actually got a real welder to do the job, it looks like he welded it all the way around.  I don't know if I trust it though. They wouldn't weld in the brace they said they did not see what it's function is.. I thought it was obvious.  Anyway, I like the Henderson part with the WHiplash
brace....Looks strong  Pics in the next few minutes if I have them on my computer at work
 
I just got off the phone with Henderson and the price is $210 for their idler pivot assembly.  They also have another kit that's not advertised, but it consists of their part plus Cognito's kit for $480.  I requested them to send me pictures of the combined kit, but he won't be in till tomorrow.  From what I can tell, the Cognito piece is their pitman & idler arm support kit.  http://cognitomotorsports.com/store/page24.html

That's not going to work for mine since the drag link is unique to the ProComp lift I have.  I already have heim jointed support on the lower side of the drag link, and really the only thing swaying is the idler arm, which will ultimately kill my tires.

Surprisingly enough, the AV still tracks straight as an arrow down the road with no vibes.  Turning the wheel to make a turn from a stop sounds like you just lost the front end.

Anyway, it's time to get the ball rolling.  I'll be putting in my order to Henderson soon.  Hopefully I'll get their pics too. 


 
suthrncop66 said:
the last picture needs to be rotated, the round bar on the left is the front behind the bumper.

Like this.  That's quite a bit of bracing in there.
 

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Yeah thats it.  mine drove straight too.  At least for me it did, my wife had trouble driving it, kept saying it was all over the road.  I didn't notice, even had it on the highway....but the third time it broke after taking it to the shop, the one that kept F&**%ing it up, it hit the transmission lines and busted one and crushed the other...Be careful, that time I also lost most of the steering, had to turn the steering wheel about 4 times to get the tires to move...lucky it happened coming out of my yard..
Good Luck and let us know what you decide.
 
I got the pics from Henderson and have an e-mail I'm waiting on to elaborate on the heim and bracket placement.  I can't quite figure out where they would go, especially the polished bracket.  For the moment, here's the picture of their $480 kit.  I'll post up when I get a response.
 

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BlackAVwbh said:
From the lack of responses it looks like you may be forging the way into new territory here.? I for one am every interested in what you choose and how it performs because now that the majority of my steering linkage has been replaced with beefier parts, the stock idler pivot assembly is on my mind constantly...I'd rather upgrade before it fails.? Keep us "posted".
I totally agree....I have also beefed my set up but I also know that is one of the major weak links.Please keep us posted I think I will also do some research of my own.
 
BlackAVwbh, that's the one.  They sent me a bunch of pictures yesterday, and it's really straight forward.  In your pic, they still have the factory pivot assembly.  Mine is pretty well gone.  The frame brace is even more important than the  heim and bracket supports.  One thing that concerns me is that once the metal suppirt is placed under the pitman and idler arm, you don't have many threads left for the nut.  Guess that's why they provide Loctite-red. 

Here's one of the pictures I got on a hummer with the frame brace I want to do.
 

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Mine was braced similar to that and it broke again....I recommend bracing it strong...and then you have no more worries..
 
The triangular style frame brace from Cognito looks plenty stout.  I would imagine the real strength comes from the qulaity of the welds to the frame rail and the idler mounting bracket.  There has to be the correct amount of heat penetration into all the metal surfaces for them to truely meld together.
 
Just ordered the Cognito idler arm assembly.  Now I need to see what all needs to come out so I can lay a bead for the gusset.  I talked to them about the pitman and idler arm support and determined that with the ProComp drag link, it won't be needed since the lower link is already supported with heim's.
 
suthrncop66, I noticed on your brace that the tranny lines look like they're resting on top of the brace.  Do you have some fuel line wrapped around them or are they contacting?  I noticed after I took off the skid plate that I may have clearance problems with my gusset and the lines.  Not that big of a deal, but I wanted to make sure yours aren't rubbing.

I need this part like yesterday because it's soooooooo loud right now.
 
Thanks for looking out, but that isn't mine.  I am having it done next week similar but a little different.  That is the pic from Whiplash.  They did it to their truck and sent me the pics.  I am going to have mine braced at an angle with 1 1/4 inch tube instead of two inch.  The shop is going to run the square tubing at an angle and make a triangular shape with the bracket, brace and frame.  They are going to do it front and back.
 
UPS paid me a visit yesterday, and the parts are here.  Literally, there is no comparison between OEM and the Henderson part.  It's solid to the tune of about 8lbs.  The gusset has a little to be desired.  It's not as thick as I was hoping, and I will probably fab my own out of 1/2" plate, or 1.5" square tube.  I'll install it this weekend.
 

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