I was thinking cut a new slot or drill new holes but isn't there a spring inside somewhere? wouldn't that take up the slack? Have you cleaned all old grease and maybe dirt out. Could something be binding the threads. If I remember right I used to tighten the adjustment screw until I ran out of threads and the cotter pin was past and not in contact the plug because it was in too far. I guess what I'm saying is the replacement parts wore a lot faster than the ball. When the steering ends its travel I have found that it compresses in a little at those ends. On another thought If your steering is very tight you could be getting compression at those places which would look like play too.
Last edited by 48jim1ton; 01/13/2013 9:36 PM. Reason: another thought