69-er

OK, anybody who has experience in rebuilding steering boxes please respond!

I replaced the input, (stub shaft), seal today with the box installed in the car. As I was removing the adjuster plug I didn't notice the shaft was coming out with it as my hand was covering the entire scene as I was gripping the plug. I reassembling it and the plug tightened down about a 1/2 turn short of my index marks. The shaft's spline flat wasn't in the correct clock location either. Well, I knew I had nothing to lose so I pulled out the shaft slightly and tried different ways of inserting it. I was able to get the flat in its proper spot but still was short 1/2 turn. I have been noticing the shaft goes in at different depths and was finally able to align my marks but the now shaft can move in and out. The plug is not taking out the end play. It looks like the plug could screw in more as there seems to be an excess of threads showing. The plug is not going to screw in any more.

So, is there something going on inside box that is preventing the shaft from going back in its original position? I rebuilt an identical box years ago but I can't remember the details other than it was a PITA. Am I looking at disassembling the box and starting from scratch to assemble it? Or maybe just a partial disassembly. I would love to be able to leave the recirculating ***** in place. I am wondering by pulling out the shaft these ***** are moving to places they shouldn't be. I need to look at a video to re-familiarize myself with the guts of this box.