I have used the magic word twice. The first time it got me a replacement steering gear. The second time, it got me nothing.
In my first post, I mentioned readjusting the gear and getting good results for a short time. I made some notes when I did this and found out that due to poor wording in the service manual I did not understand that the ball screw portion should have a preload to avoid play in the steering. Makes sense. However, this is not adjustable. You either have it or you don't. In my case, I didn't have any preload torque. The manual says 7. 5 to 14. 5 in-lb at 180 to 270 degrees off-center. At this location, I could turn the shaft with a thumb and forefinger with no effort. I think that readjusting the over-center torque gives a good feel that shortly disappears due to the ball screw play.
So, what's wrong? Without a tear down, I can only suppose that the rack piston or worm shaft are out of spec in regard to size, or when the gear was assembled the balls were not installed properly. There are two different size balls and they must be installed in alternating sequence (1 large ball, 1 small ball). This is printed in bold in the service manual stating that this maintains proper wormshaft preload.
When I go back for another steering gear, wherever it may be, I'm going to demand that the preload (off-center) torque and the over-center torque (pitman shaft adjustment) be checked while I witness. I don't want another piece of crap installed.
Some people may think I'm crazy for going through all this on my own, but I believe that understanding the problem is a good way to avoid it again. I've only spent about a day all total checking into this. On the other hand, I guess I could go dealership "hopping" and spend weeks. I did have a laugh the other day when I got the DC promotion in the mail to extend my warranty. Why should I?
I will continue posting until my problem is solved.