Excessive play after steering gear box and intermdt shaft replace

Manual Steering Column with JL4) or
Steering Wheel Position Sensor Replacement (Power Steering Column with JL4) ?
Preliminary Procedure Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
1
Steering Angle Sensor Adapter
2
Steering Wheel Position Sensor
Procedure Disconnect any electrical connectors as needed.
Tip
If reusing, secure the old steering wheel position sensor before removing it for proper alignment upon reinstallation. Refer to Steering Wheel Position Sensor Centering .

Callout

Component Name
Notice: Secure the steering wheel utilizing a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:
?€¢
The steering column
?€¢
The intermediate shaft
?€¢
The steering gear

After disconnecting these components, do not move the front tires and wheels. Failure to follow these procedures may cause improper alignment of some components during installation and result in possible damage to the SIR coil.
Preliminary Procedure Remove the steering column. Refer to Steering Column Replacement .
1
Intermediate Steering Shaft Bolt
Procedure Remove the steering column boot seal in order to access the intermediate steering shaft bolt.
2
Intermediate Steering Shaft Nut
Notice: Refer to Fastener Notice in the Preface section.
Tighten
47 N?·m (35 lb ft)
3
Intermediate Steering Shaft
Tip
?€¢
If necessary, scribe location marks between the intermediate steering shaft and the steering column and the intermediate steering shaft and the steering gear to mark their alignment before removing.
?€¢
If replacing the intermediate steering shaft, transfer any scribe marks from the old one to the new one.

Callout

Component Name
Notice: Secure the steering wheel utilizing a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:
?€¢
The steering column
?€¢
The intermediate shaft
?€¢
The steering gear

After disconnecting these components, do not move the front tires and wheels. Failure to follow these procedures may cause improper alignment of some components during installation and result in possible damage to the SIR coil.
Preliminary Procedures

1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .
2. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement .
3. Disconnect the intermediate steering shaft from the steering gear. Refer to Steering Gear Replacement .

1
Steering Column Nut (Qty: 4)
Notice: Refer to Title not found in the Preface section.
Tighten
25 N?·m (18 lb ft)
2
Steering Column
Procedure

Disconnect any electrical connectors as needed.

If equipped with AN3, disconnect the automatic transmission range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement - Column .

Transfer any parts as needed.

Hi,in the past when doing jobs on cars to do with the steering rack ive always had to replace as parts are non repairable.
hope this was some help.

it is called a steering box not a gear box and the adjustment will be in the steering box or in the rack and pinion

this might help:
Here is the Technical Service Bulletin that maybe of help, worth looking into but can't guarantee that it would fix your problem Steering - Steering Column Clunking When Turning TECHNICAL Bulletin No.: 01-02-32-001P Date: November 25, 2009 Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front Of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Replace Intermediate Shaft As Directed) Models: 2001-2004 Buick Regal 2005-2008 Buick Allure (Canada Only), LaCrosse 2000-2008 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to add the 2008 Buick LaCrosse/Allure. Please discard Corporate Bulletin Number 01-02-32-001O (Section 02 - Steering). Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver.
1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle. 2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. 3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. 4. Drive the vehicle straight ahead at idle speed while applying and releasing the brake pedal. Listen/feel the steering wheel for the clunk/noise condition. 5. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue with the correction. Correction DO THIS - Replace the intermediate shaft DON'T DO THIS - DO NOT lube the intermediate shaft Replace the existing intermediate shaft

Check the steering intermediate shaft connection to the steering gear box, its slip shaft and the connection to the stering collumn. if those are ok, its probably slop in the steering gear box. Some of that can be adjusted out on the gear box by your mechanic. You will see either a flat head cut or hex head inset with a lock nut on the top of the gear box. Loosening hte lock nut and tightening the bolt to factory torque setting then releasing it the appropriate specified degress will reset the gear box back to factory settings. Beware if you set this wrong you will cause your steering to bind when turning. Therefore only let a qualified mechanic do this for you.

here hope this helps for a 98 model but very similair

1998 GMC Truck Jimmy - 4WD ' Blazer, Bravada, Jimmy, S10 Pickup, Sonoma VIN S/T Service Manual ' Steering ' Power Steering System ' Repair Instructions ' Document ID: 416283
Steering Gear Replacement (4WD) Removal Procedure Tools RequiredJ 24319-B Steering Linkage Puller
Notice: Do not rotate steering shaft after steering column has been removed. Damage to SIR components may occur.

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L.




2. Place a drain pan below the steering gear.
3. Remove the inlet and the outlet hoses from the power steering gear.
Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt from entering the system.




4. Remove the intermediate shaft shield from the steering gear.




5. Remove the lower intermediate shaft coupling bolt.
6. Draw alignment marks on the lower intermediate shaft coupling and the steering shaft.
7. Remove the lower intermediate shaft coupling from the steering shaft.
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Remove the steering linkage shield. Refer to Steering Linkage Shield Replacement in Steering Linkage.




10. Remove differential carrier shield mounting bolts.
11. Remove the differential carrier shield.




12. Remove the pitman arm ball stud nut at the relay rod.




13. Disconnect pitman arm from relay rod using J 24319-B .




14. Remove the steering gear mounting bolts and the washers from the frame.
15. Remove the steering gear.
16. Remove the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.

The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 1. Raise and support the vehicle. 2. Remove the stabilizer shaft. 3. Remove the tie rod ends from the steering knuckles. Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of steering control which could result in personal injury. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 4. Disconnect the steering intermediate shaft from the steering gear.

Copied from AutoZone.com:

1. Before servicing the vehicle, refer to the Precautions Section.
2. Turn the steering wheel to the straight ahead position and remove the key from the ignition.
3. Turn the wheel counterclockwise in order to lock the steering column in place.
4. Raise and support the vehicle.
5. Remove the front wheels.
   WARNING Do not rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur.
   
   
   Fig. Steering shaft pinch bolt
   
   
   Fig. Steering gear mounting
   
6. Remove the steering gear to intermediate shaft pinch bolt and discard.
7. Disconnect the intermediate shaft from the steering gear.
8. Remove both steering gear outer tie rod to knuckle nuts and discard the nuts.
   WARNING Do not attempt to separate the joint using a wedge type tool.
   
9. Separate the outer tie rods from the steering knuckles.
10. Remove the steering gear bolts.
11. Remove the rear transaxle mount.
12. Carefully remove the steering gear from the frame and the vehicle through the LH wheel opening.

To install:

1. Install the steering gear to the frame through the LH wheel opening.
2. Install the steering gear bolts. Tighten the bolts to 81 ft. lbs. (110 Nm).
3. Install the rear transaxle mount. Tighten the rear transaxle mount to frame bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
4. Tighten the rear transaxle mount thru bolt. Tighten the thru bolt to 74 ft. lbs. (100 Nm).
5. Connect the intermediate shaft to the steering gear.
6. Install a new intermediate shaft pinch bolt. Tighten the bolts to 25 ft. lbs. (34 Nm).
7. Install the outer tie rods to the steering knuckles.
8. Install new outer tie rod nuts. Tighten the bolts to 44 ft. lbs. (60 Nm).
9. Install the front wheels.
10. Lower the vehicle.
11. Adjust the toe if necessary.

Removal Procedure

Notice: Do not rotate steering shaft after steering column has been removed. Damage to SIR components may occur.

Lock the steering column through the access hole in the steering column lower trim cover using the J 42640.
Remove the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement in Powertrain Management.Remove the intermediate shaft shield from the steering gear.Place a drain pan below the steering gear. Remove the pressure and the return hoses from the power steering gear. Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt from entering the system.Remove the lower intermediate shaft coupling bolt. Draw alignment marks on the lower intermediate shaft coupling and the steering shaft. Remove the lower intermediate shaft coupling from the steering shaft. Remove the pitman arm. Refer to Pitman Arm Replacement.Remove the steering gear mounting bolts and the washers from the frame. Remove the steering gear.
Installation Procedure


Install the steering gear. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear to the frame washers and the mounting bolts. Tighten Tighten the power steering gear to frame mounting bolts to 75 Nm (55 ft. lbs.). Install the pitman arm. Refer to Pitman Arm Replacement.Install the lower intermediate shaft to the power steering gear. Ensure that the alignment marks line up. Install the lower intermediate shaft coupling bolt. Tighten Tighten the lower intermediate shaft coupling bolt to 35 Nm (26 ft. lbs.). Install the pressure and the return hoses to the power steering gear. TightenTighten the pressure hose to 25 Nm (18 ft. lbs.) for the vehicle equipped with the 2.2L engines. Tighten the pressure hose to 30 Nm (22 ft. lbs.) for the vehicle equipped with the 4.3L engines. Tighten the return hose to 25 Nm (18 ft. lbs.). Install the intermediate shaft shield to the power steering gear. Install the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement in Powertrain Management. Unlock the steering column by removing the J 42640 from the steering column lower steering column trim cover access hole. Bleed the power steering system. Refer to Bleeding Power Steering System in Steering / Service and Repair.

Lube your intermediate steering shaft. It is very easy. Remove the bolt in the shaft that you can see from under the hood and push the steering shaft up toward the firewall. Where the shaft goes into itself place some grease and work it back and forth. This will last quite a while, but is easy to do again if need be. Replace the bolt and you should be go to go. The dealer will charge you $150 to do the same job. The knock goes away as soon as you test it out.