I'm going to try and describe this as best I can... here goes...

When I apply the brakes between 40-60mph, I get a pretty bad vibration in the STEERING WHEEL, it goes away at anything outside of that speed range. Everything appears tight in the suspension and the brakes are new (rotors/pads)

Here is what i THINK might be part of the problem...

If i center the steering wheel, it's 2.25 turns to full lock one way, and it sticks at full lock.
If i turn the wheel the other way, i only get 1.75 turns to full lock and it doesn't stick. There should be no sticking.

Anyone have any ideas?

Tyson: Rack end bushing was done and the inner & outter rods as well.

So what can cause brake vibration if it's not rotors! I'm loosing my mind here.

 

I just went out and took the boots off the steering rack, turns out the big washer that was SUPPOSED to be on the very inner end of the inner tie rod, was to small and it enabled the inner tie rod to push the rack end bushing into the shaft!!!! Now there is no freaking way I can get the bushing back out.

That accounts for the sticking and ability to make more rotations on one side. But would it account for my vibrations?

 

here's a picture to help explain.

 

Sure why not, whoever put your rack together had no idea what they were doing and it puts in question the whole install. It wasn't done right, so why would you expect it to work right?

Start with fixing the problem. Figure a way to get the bushing out. dismantle it completely if you have to, or just find a new one.

And you never mentioned if you tightened the pinion either.

And make sure the universal joints and clamps are tight too.

 

Clamps tight, pinion gear adjusted...

I'll have to pull the rack again to get that bushing out. I have a spare Si rack that i'll probably just end up putting in instead.

 

Tyson:

Is there supposed to be ANY play on the shaft where the rack bushing is? If i turn the wheel full left lock so the shaft is fully protruding from the rack bushing, i grab it and jiggle it around, there is a small amount of play. No clunking or noise, but still trying to sort this out after years and years.

 

None

 

So if after a new bushing, and it still has a bit of movement, i need a new rack?

 

You forgot to adjust the pinion, didn't you....

 

If i tighten the adjuster anymore, i cant turn the wheel.
The slight amount of play is only from the rack side.

 

you really need to check out the whole front end for tightness.

the REB was a likely spot since it was installed incorrectly. time to keep searching if its still going on.

in case anyone thinks its just the rotors, when the suspension is tight, and you have bad rotors, its still just a mild pulsing felt at the wheel. not shaking. shaking means play.