SWB steering issue

[cmpski]

I'll start by saying I had the front suspension off to move the gas tank to run hard fuel lines through the tunnel. I've had the front suspension off 3 or 4 times without this issue.
When I button up the front suspension and steering box the splined shaft that connects to the steering box is off so far I can barley get the bearing on as the shaft is actually pressed up against metal by the upper mounting bracket hole. If I tighten the bearing in place it puts a strong side load on it and it clicks at about dead center and also causes the shaft to pinch to one side when the steering wheel is off. I've never run into this before. When I loosen the two bolts that hold the rack to the crossbar it goes into place. I tried loosening all front suspension contacts in case there was a bind somewhere and carefully retorqued the bolts. It didn't help. When the steering wheel is not connected to the steering box both the steering wheel and the steering box move all the way in both directions smooth as silk.
What gives? Do I need to rebuild the box, tie rods twisted, or?
The shaft should be pointing up not down.
Chris

[Uwon]

Odd. Do you have those large spacers (pucks) that lowers the steering rack to reduce bump steer? If so, one may not have been re-installed.
Johan

[cmpski]

No pucks. I'm going to release the tie rods and see if there slightly twisted.

[cmpski]

I released the tie rod ends to see if they were off. It didn’t help. When the steering rack is just a little loose and pressure is on the rod to move it in the proper position you can see the whole rack wants to rotate. There are no pucks or washers between the rack and cross bar.
I put a long bolt in the rack and wiggled it to see if there was play and couldn't feel any.

I went home and blew this picture up and noticed a 180 degree scratch. What do you think? About the only thing left that I can think of is pull the rack and look inside. I would appreciate some feedback here.

[cmpski]

I'm replacing the crossbar.