Here is a picture of the gap b/t the pitman and the steering gear is that correct? Is it visible? The sway bar was kinda in the way. Also on the open airhat my bolt is longer than 4in like the diagram says I think mine is near 8.5 inchs long do I need to cut it?

 

Looks to be about the same size gap mine has.

 

So then the top of the pitman doesn't fit snug against the gear.

 

Regarding the heater core, I did that job a while ago myself, took patience, but it wasn't hard.

I found a great writeup on this site, which I think I found in the DIY section, here's a link to my thread, you may find some useful info in it.... at least I hope.

https://dodgeforum.com/forum/2nd-gen...eeze-gone.html

 

No. The shaft is loose even with a brand new one. If the arm was tight against the gear box it would bind.