Steering Rack - I don't think this is normal
 

I got my new steering rack under warranty (Thanks Pelican!) but it appears there might be a problem with it. At a particular point in the shaft rotation, it binds. Imagine a 'cam', with more pressure as you get to the top of the lobe, and then a release as you start down the other side. It's like that.

I don't think this is normal. The one I'm replacing is fairly 'frictive' but doesn't grab at any one spot. I made a small reference ink spot on the housing and the shaft, and it does it at the exact same spot every time.

So, does this warrant rejection of the part?

Did you align the inner ends of the tie-rods properly? One of mine (914-6) had turned accidentally while adjusting the toe and that caused the feel you described ... until it went away, then I looked under there and found the end was bent. Got a new (used) one, installed at correct angle, and all was fine.
Mark S.

The problem isn't with your rack, Thom. It's with the steering shaft u-joint. It is likely at an improper angle due to bump steer spacers, too much pre-load, or simply rusty or dry.

If you loosen the clamping bolts on the u-joint and tap it lightly with a small hammer to get it to ride up higher on the splines toward the steering wheel on one end, and down farther on the splines on the rack end, it should releive the pre-load.

Lubricate all the joints with penetrating grease while you are at it.

It wouldn't be a bad idea to remove the u-joints altogether to make sure they are moving freely and aren't worn out.