After installing my new UMI a-arms, Koni struts, UMI strut mounts, UMI srpings, and ProForged steering I'm getting a pop sound only when I turn the steering wheel to the left.
At the same time I also replaced the input shaft seal in my steering gear box and attempted to reset the preload on the thrust bearing. If I loosen my steering gear box worm gear preload it goes away, but then I have in and out play on the steering input shaft and a huge amount of steering wheel play.
I checked my gearbox to frame mounting torque and everything else is torqued to spec. Any ideas?

Update: If I apply upward pressure on the steering shaft while someone turns the steering wheel it no longer makes the pop/clunk noise. If I apply downward pressure it makes the noise louder.

 

So first question, are the inner tie rods installed with the castle nuts facing the front of the car?
as in, if you look directly at the steering linkage, are the inner tie rod castle nuts facing you?

 

 

Did you make sure you centered the pitman arm with the gear box travel limits?

This video is an excellent illustration of how the steering gear depth setting works.

 

considering the position of the idler and pitman i do not believe you can install the inner tie rods backwards. Make sure the center link is level and that there is clearance throughout lock to lock. the idler is difficult to tighten at times due to the bolts being hidden inside the subframe rail, make sure these are tight. The rag joint and the firewall column bolts should be tight. then go inside yer box if that don't solve it, if you used an air tool on yer pitman bolt, you may have exacerbated or caused damage to an already old box.

 

Thanks. I leveled the centerlink to 3mm above the bottom line of both control arms. Idler and pitman are centered both parallel with chassis when wheels are forward. I replaced the input shaft seal on steering gearbox and checked lock to lock center point before and after reinstalling it. I torqued all bolts/nuts to recommended torque settings. I didn't remove pitman arm and did not use impact gearbox. I replaced ragjoint with the astro shaft sold by robertFrank on this forum and it appears to be clocked correctly.
Note: The popping seems to only happen when turning the steering wheel to the left, especially if the steering has been first turned to full lock to the right.