My 02 has a bump/rattle that I feel in it when going over the slightest uneven terrain! I thought it may be the ball joints but they checked out? Are the shafts on these week and need to be beefed up like on the 1st gens? Thanks in advance?

 

There is an upgarde kit from BD that is highly recomended for Gen 2's, as the steering box is apprenly not supported very well. It can be bought from Genos, about $215.
There may be other suggestions, but I know this is one upgrade highly recommended to people who plan to keep their trucks long term. It is also recommended for heavy towing.

 

Had the same issue over the past few months. The ball joints are good, but the tie rods and track bar went bad. The intermediate shaft has also been known to go bad on second generation. I decided to replace the front end components first with Moog (lifetime warranty) and next will be the intermediate shaft, might wanna do a search for Borgenson steering shaft.

 

Borgeson is about $300. I talked to one person that provides steering upgrades that recommended against them. Said that at least off road, they lock up at the joint that slides. You'll have to determine where the slop is coming from before you can decide on a remedy.

 

Have you checked your track bar where it attaches at the axle? I had a problem with that on my 02' & i re-seated it & tightened track bar back down. Got rid of popping noises....

 

Mstep3 I have not, but will do! Its not a popping noise though, its more of a bumping and something loose feeling that I feel in the wheel! Does that sound more like the shaft or the track bar?