I had a 3 turn 84 rack that I was going to rebuild, but I broke the housing getting the pinion out (forgot the snap ring-DOH!). I also had a 3.5? turn rack from an 86 SE, so I rebuilt that and put the 3 turn rack and pinion in it. Now it feels kind of "ratchety" when I turn it (on the bench) unless I lessen the preload to the point the nut is barely engaged in the housing. Was putting the rack and pinion from the 3 turn rack into the 3.5? turn housing a bad idea? Should I put the slower rack and pinion back in? Will pulling the preload bushing out and rotating it 180 degrees help?

Oh, and what's up with the bigger, short bushing in the left end of the rack? what does it do?

Has anyone experienced this?

------------------
1986 SE Aero coupe.

3.4 DOHC swap is complete and running, now just have to finish the rest of the car...

my only guess is being the pinion for the 2 different racks has different amount of teeth, it may be different size/diameter as well.

Correct. I'm using the rack and pinion from the faster rack.

Anybody? Should I put the slower rack and pinion parts back in?

My experience has been that all racks are a bit "ratchety" when uninstalled. The combined effects of the weight on wheels and the large diameter steering wheel smooth out the perceived motion when installed.

It is definitely best to set the pinion pre-load to factory specs.