Originally Posted by TDI-Minnie
Maybe I'm crazy but I simply put a wrap of duct tape around the ball mount before inserting into the hitch receiver.
No rattle and no wear.
New duct tape every so often.
This has worked for many years.
I don't think the wear will ever gt to the point that it's dangerous, but more noisy yes. Iv'e used tape also with great results. I tried another trick and that was silicone sealer to fill the voids. Works very well but if you frequently remove your hitch, it could make it difficult.
Last resort was/is a guaranteed fix.
With a MIG welder, I welded a bead along the inserted length and center of the ball mount insert bar, forward and aft of the pin hole on the sides, and the full inserted length on the top only with two parallel rows of weld bead.
The purpose of two rows on top is to remove any and all twisting movement of the bar.
The welds were then adjusted by way of grinder to attain the proper fit. This took out all of the rattle and never had another problem for years after the fix.
This fix is way less costly than replacing parts, and the weld is now acting as a wear pad for future adjustments, that you will most likely never need.
Do not weld beads on the bottom of the slide in bar, this is where most of your load is concentrated and it needs the full flat surface in support of that weight.
The welds are actually harder than the other areas of metal on your bar after it cools. They will not wear very much in use, and can easily be built up more at any time if ever needed.