To be honest, 1/4 turn doesn't sound all that bad too me.
I'm not sure you'd get that out with the bushings/bearings.
And I'm not sure you can flip the sector gear... just can't picture it - but thought it was a sort of one way thing - but you could be right. If so, that might help.
The gear getting worn only causes some of the slop. It's more of a combination of a little slop here, and a little slop there that adds up.
I had a full 180 degrees of free play - from 9:00 to 3:00 before the wheels even thought about turning. Another 15 degrees either way before they would actually start moving appreciably.
Maybe 20% of that was fixed by tigtening up all the tie rods.
I'd say another 50% came from the worn square hole in the steering arm at the bottom of the steering box.
The remaining 30% was fixed by new bushings and bearings in the steering box.
Even after all that, it's not completely tight, there's still a good amount of free-play. But it's WAY better than it was.
It went from undriveable to a pleasure to drive.
I honestly don't even notice the slop that's left now while driving it.
And, the way I look at it is that it's a 60 year old machine, you've got to live with a little looseness. I'm not sure what they were like from that factory, but I'd guess there was some slop to begin with.
So for me it's a case of diminishing returns. I don't feel like spending big bucks and time chasing a few degrees of free play.
I'm sure with new gears and more work I could get it tighter, but it really is quite useable as is.
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