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When I did the final inspection before removing the old steering rack tonight, I removed the belly pan, climbed underneath and had the wife saw on the steering wheel for me. Er, um, well, I found the problem was that the U-bolts that hold the rack to the cross member were loose... VERY LOOSE! The rack was moving nearly 1/4 of an inch side to side, ergo steering slop. I tightened up the 13mm headed nuts on the U-bolts after centering the rack and all slop disappeared!
I hope my new-found shame will prevent someone else from buying a rebuilt rack they didn't need in the first place! I have to assume that the new U-bolts that come with a rebuilt rack give over time and loosen up a bit, so perhaps following a rack replacement rechecking the nut torque a few months later might be a really good idea! Yes, the rack itself is fine.
jorrell
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92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!
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Power steering rack failure modes [200][1992]