I'm having some real PITA problems with these stupid racks..... The one I took out, has about 1.5 cm of play on the driver's side (in the rack around the bellow) while installed. While off, the main shaft will move about half a centimeter in relation with the rack. The one I just put in had slight play, which I guess it should, but it felt really good and tight. After installed, that side still has as much play as before! Whats the deal? The inner tie rods are quite new and are tight.

Basically, my question is, besides the rack bushing, what goes wrong with these things?

Try adjusting the pre-load on the rack. Loosen the castle lock nut on the plunger cap, and bottom the cap out.

You don't crank that cap down untill it doesn't turn anymore, just turn it in untill it starts to get hard to turn. Turn the cap back out 60° , and hold it in that position while tightening the lock nut.

The plunger cap is that thingy that's perpindicular to the steering shaft , pointy upwards.