01 Express 3500 Cut Away 5.7 80K Every thing has been replaced including rear leaf springs, and front coiils, steering box ect everything! Been check on a frame machine and no issues. Right front upper control arm is maxed out, yes bracket plugs are removed. There are no offset bushings or ball joints for this year.

Has anyone slotted the lower control arm bracket to move lower control arm in to gain adjustment?

 

On my 01 express 3500 we maxed out camber and upon measuring the frame rail approximately under the tranny was 4.5mm narrow to spec. No indication of an accident so had to come from factory that way Had the top wishbone attachment point moved inwards a bit on drivers side and it helped a bit. My alighnment guy is excellent but has never seen anything like this before. He now suggests trying a new steering box as he’s heard they tend to leak from seals internally. Where you have already changed yours with no improvement I’m hesitant to spend the money. It’s only got 60,000 miles so unlikely to be worn out. I hope you have better luck than I did.

 

You are lucky to have a good alignment guy, one thing I found is the average alignment tech does not have a clue. They tale your money and send you out the door even though it is not in spec. It was not until alignment #5 that the alignment tech threw in the towel and told me there was something wrong. He had no idea what was wrong and told me to find an alignment specialist. I have a good alignment guy now but out of 11 alignments I only found 3 that have a clue and only 1 that offers a solution.

The steering gear did make a difference, everything I have done has made a difference but not fixed the wandering. It is going to wander until the alignment is brought into spec.

My wandering was only white knuckle one time. After sitting for several months it was handling horribly, that time I found that the front end had not been greased in long time and was dry. Even after a grease job the upper idler arm brackets were not greased and bone dry. Note this was after several alignment techs had worked on it and did not notice the front end was not greased.

 

I've taken a vehicle in for an oil change one time in my life. They changed the oil and didn't grease anything. When I called them out on it they said it wasn't covered... I had to show them on their invoice where it was listed. Then they had to find a grease gun and figure out how to work it. I told them "there are 13 grease fittings, make sure you get them all". They weren't happy with me! At least there are fewer fittings on a GM van but some of them like the idler bracket are very hard to get to. I bought and installed the extension for it which helped a lot.

https://www.rockauto.com/en/moreinfo...08860&pt=13418