Hey there, I think I had the exact same problem you are describing. In my case, I fixed everything else under the front end, and still didn't get rid of it until I replaced the intermediate steering shaft (easy, two bolts, and a lot of contortionism to get your arms in there to work on it). The odd thing was, the existing one did't feel like it had any more slop in it than the new one. Even when I pulled it out and had both of them sitting on the bench, the only difference I could feel was simply the ease of movement of the older one's u-joints, but they didn't have any "slop" in them that I would expect to cause the noise. Either way, there must have been something wrong with it, cause once the new one was in and torqued down, the noise was gone, and haven't heard it since. Hope this helps.