Steering internals binding/looseness?

[maxdef]

I have spent a long time trying to isolate a couple steering issues, mainly wandering and a clank over bumps. The steering response is tight, and all the components are <30k miles/4 years old, but there is always a need to correct direction, and freeway speeds are miserable. I've noticed that if I shake or tap the lower intermediate shaft, there is a looseness and metal sound coming from what seems like the section where the control valve internals are. A couple years ago I got an alignment after swapping UCAs and noticed right away the wandering issue. Specs looked right, and I've since learned about the steering tensioner/rack guide and wondered if the tech somehow touched that during their alignment struggles. I want to check the rack guide torque but its hard to get to when installed so that's TBD.

It got a little more interesting the other day- I replaced the passenger ITR as I noticed some slop and no resistance in the socket. When I was done, my steering started to make a groaning/almost binding noise at center, but moving side to side was fine. Checked under the boot and everything looks normal. It's more noticeable at slow speeds like turning into a parking spot, but that might just be a lack of other road noise letting me hear it.

Right now, I have 2 new OTRs and the new driver ITR ready to install, but I can't figure out this new noise and whether I should even bother putting on the new parts if the internals are becoming problematic.
-Has anyone experienced this from their rack?
-Should I be rebuilding (never done that) or replacing it (can I buy just the rack, as I have all new ITR/OTR?)?

 

[BackOff]

Low caster can cause wandering, 3degrees or more helps a ton.

Groaning maybe empty/burnt power steering res.

Clunks and clanks can be pretty much anything, balljoint, skid plates, control arms, exhaust, bushings, swaybar, battery tiedown...you name it.

 

[maxdef]

Low caster can cause wandering, 3degrees or more helps a ton.

Groaning maybe empty/burnt power steering res.

Clunks and clanks can be pretty much anything, balljoint, skid plates, control arms, exhaust, bushings, swaybar, battery tiedown...you name it.

I completely get that, and I've likely read all these repetitive and often unsolved threads to narrow things down.
-OEM LCAs are 4y/30k old and don't seem to have any issues
-Dobinsons UCAs are 2y/12k old and seem fine
-Skid plates have been off since before the tie rod swap and testing shows no difference
-Very few original bushings remain on this truck, and anything up front is within 3 years old
-Battery healthy and does not move, especially at rest when i can easily replicate the issue.
-PS fluid (ATF) has been consistent since it was filled 4 years ago, and I had also swapped the healthy, red fluid because maintenance during this job and properly burped it.
-PS pump is healthy and makes no noises, so my spare will continue to sit quietly on the shelf

It is important to note this 100% started after swapping my passenger ITR. When I tightened it down, the main shaft that the ITR threads into was rotated slightly towards front. After a day of thinking I did something there, I slightly rotated it back to where it was but no change. I had also checked and the base of the ITR is seated properly with the claw washer.

I can replicate the sound by firmly tapping/hitting the intermediate steering shaft, and the noise very much appears to be down at the rack. If i rock the truck back and forth from the UCA, I can start to hear some similar looseness (not at the UCA) but its kinda vague and hard to pinpoint. When I had someone turn the steering while parked and I crawled around underneath, it still only makes the quick groan at steering center when going left or right, and the feeling and sound both appear to be at the tensioner/gear area. I will get a video up shortly.