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estodd,
It's been my experience that the slightest burr on either the shaft or pitman bore will create hours of frustration.
What I usually do is use fine Emery cloth (180 grit) and 'Shoe Shine' the shaft thoroughly and until it's brightly polished. I then use a piece of All-Thread that's split at the end so it will accommodate a few wraps of the same emery cloth. Using a drill, clean and polish the bore of the pitman arm....and finally, use a fine, small flat file to clean the guide key-way on the pitman arm AND the shaft.
Nine times out of ten, the additional work pays off and the assembly goes together.
Shartel
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