After chasing the U-Joint culprit, finding and replacing the lower u-joint, then locating the upper shaft and u-joint (in the pouring rain-I really thought the u-joint fix made the most sense) and replacing it, all to no avail. Same nasty grab at 45 degrees off center to the right and left, and even seemed to get tighter with replacement of the u-joints. Fortunately, I was dealing with a good gear box rebuilder that tried to assist over the phone long distance. They produced the direct match rack and pinion - the cam style, as opposed to the ZF style they initially provided. Just installed it this past saturday, and what a difference the correct part makes. Smooth as silk steering, no shudder or pull. When I replaced the first rack, I noticed it was slightly different but still bolted up with no difficulty. I also replaced the lower ball joints - one was bad. With a complete four wheel alignment, all is good. That Volvo steering and road feel is back. The rack company was referred by members of the brickboard - Jorgen automotive. Good company. As for the U joint parts - Volvo no longer carries a new upper shaft/U-joint, so junkyards are it. The 940 and 960 also use the same part. If the u-joint doesn't grab or bind in your hand, it isn't the problem - plain and simple. Thanks for all the help. The Coupe rides again.
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