Just replaced the steering gearbox as the last upgrade after rebuilding the front end last summer. The old box had about 1 inch play in each direction. The after installation test drive was the best the car has ever handled. Box was installed in about 65 degree weather. About a week later and about 40 degree outside, after starting the car and before putting it in gear, there is about 1/4 inch of play in both directions. I could actually feel the worm gear/sector shaft teeth hitting up thru the column. As temperature goes up and the power steering fluid warms up, the play is still there, but is masked by the hydraulic action in the gear box.

Car drives straight as an arrow on a good road, so alignment is good, and everything else is still tight (would hope so with only 1200 miles on the new front end). Still, I will get an alignment check on Monday.

I would not expect a freshly rebuilt box would loosen up this fast (factory rebuild, A1 Cardone).

For all the steering box technicians out there, have you seen this before? I know that many hard parts are "reclaimed" and reused in factory rebuilds. Will a simple adjustment fix or mask a possible internal problem? I am willing to pull the box and do the adjustment on the bench per the service manual, but want some expert opinions before doing so. If necessary, I'll tear the box down, inspect and rebuild it myself since I have a rebuild kit on hand (but won't have the time for that till next month).

As part of the front end rebuild, the intermediate shaft, spindles and strut bearings were also replaced. Only item not replaced was the Idler arm, since it had only 10,000 miles on it and was still very tight.