[lee]

It could be the backlash was never properly adjusted - has it done it since day one? Here's what my Alldata CD has to say:

Steering Effort Tests
1. Measure steering effort in stand still with engine idling on concrete road. Steering effort should be as follows:
a. On engine RPM sensing type, 6.8 lbs.
b. On vehicle speed sensing, electronically controlled type, 5.1 lbs. or less in both directions.
c. On all models, if effort is not as specified, adjust backlash.
2. Measure steering effort with vehicle stopped and engine off. Ensure wheels are off the ground during measurement. Steering effort should be 3.7 lbs. or less in both directions. If effort is not as specified, adjust backlash.
3. Remove joint assembly.
4. Measure steering wheel effort. Steering wheel effort should be .51 lbs. or less in both directions. Variation should be .24 lbs. or less.
5. Measure folding torque of joint assembly. Folding torque should be 1.23 lbs. or less for long yoke or 1.90 lbs. or less for short yoke. If folding
torque is not as specified, replace joint assembly.
6. Inspect front wheels for unsteady revolution or rattling and brake for dragging.
7. Remove and inspect tie rod ends.
8. Measure rotating resistance of gearbox assembly. Rotating resistance should be 2.36 lbs. or less in straight ahead position and in all positions 2.6
lbs. or less. Variation should not exceed 20 percent difference between clockwise and counterclockwise. If rotating resistance is not as specified,
adjust backlash.
9. Measure sliding resistance of gearbox assembly. Sliding resistance should be 60 lbs. or less. Variation should not exceed 20 percent between left and right directions. If sliding resistance is not as specified, adjust backlash.

From Rack Assembly procedures, Item #6:

6. Adjust rack and pinion backlash as follows:
a. Torque adjusting screw to 14 ft. lbs. to seat sleeve against rack, then loosen screw.
b. Torque adjusting screw to 3.6 ft. lbs., then loosen screw.
c. Torque adjusting screw to 3.6 ft. lbs., then back off 25°
d. While holding adjusting screw in place, torque locknut to 43-54 ft. lbs.