An old reply but still very relevant so I'm trying my luck.
This was a very good write up. I have today replaced 4 shocks, inner/outer tie rod on both sides, pit man arm, idler arm and assembly, sway bar bushing kit and the telescope steering shaft. I also adjusted my steering box when it was out of my truck and I set it so it was firm with no play when the box was at center but then it had play once it was out of center.. Is this signs of a worn box? I have slightly less than 1/2 inch of light steering and it does feel like play when driving. It's annoying when going between slow curves as I can clearly feel the play when going past center. Before I took my box out and replaced all this I had my box set a bit to thight so steering was hard around the center but I hope I didn't kill my box with this ^^ I find it really hard to adjust out the play in the box as it's hard to know when not to adjust thighter ^^
I recall reading that if you adjust the steering box as referred to in this post, it is possible that due to wear in the common steering position, the steering may bind at the extremes of steering. The slop at straight ahead can be due to wear just in that position of the steering gear. Far right and far left get less wear in the gearbox, so if adjusted so that some play is removed from the straight ahead position, you may not have enough play at the far right or left.
It was suggested to me to adjust the steering box in the following manner:
1) With the engine off and front wheels raised, measure the torque required to just turn the wheels right and left.
2) Turn the steering wheel to near far right and repeat the torque measurement.
3) Repeat step 2 for the far left torques on the steering wheel.
4) If the torque (force required) at the far right and left is LESS than the torque required at the straight ahead position, you are safe to tighten the steering box. You can tighten it until the far right and left torques begin to equal the straight ahead torques.
I believe the steering box is designed so that the steering is tighter when on center. This helps keep the on center feel. (The caster in alignment also helps.) As the steering gear wears, it is possible to tighten the gear without binding the far right and left. But, if the gear cannot be tightened without the far right and left still being less torque than the center, it is time for a new gear.
I did this to my Grand Marquis a few years ago and it improved the steering a lot, it never bound up, and hasn't accelerated the wear in the box significantly.
My Tahoe simply needed a new box.