[westofb]

It sounds like you and put the same parts in out collumn rebuilds, yours is having slop, mine has none, so I assume yours is not adjusted just right. It's been awhile since I redid mine, but I am thinking I did my adjusts as such:
after getting the main shaft and all the bearings and what not back in the column, I put on the end cap first and tightened it down enough at that time to take the end play out of the main shaft. Next I installed the side cover/ cam follower cover, and associated parts, at this point I left the follower loose, I was more concerned about getting the side plate adjusted, again tightening the new jamb nut down as I worked the plate back and forth, if you left it too loose, it tends to want to not only have end play, but will rock a slight amount side to side, I adjusted this part so that there was good compression of the foam gasket (actually the metal sleeve it sat in just barely misses making contact) and there was no side to side movement, and of course no end play. At this point every part is back on the column, just haven't messed with the follower yet, at that point I clamped the column down (a vice would be great), added a steering wheel and began final adjustments of the follower and end plug. Putting the steering wheel on helps alot, it will magnify any adjustments you have out of wack, I started with the follower basically in the center of the gear box, I tightened it down until I felt just a slight resistance, then begin to rotate the steering wheel slowly lock to lock, while doing this, tighten the follower down, you want it making contact with the sides of the worn gear, so tighten it until you can feel it begins to put resistance on the steering itself, they back it off slightly (by slowly turning the steering, you will feel it hit it's sweet spot, is hard to explain, but as you adjust each piece, you need for those adjustments to add to the resistance of the steering itself, ever so slightly, no resistance=slop). After getting the follower set, the last piece (and the first) to be set is the end plug. With everything else adjusted, slowly turn the column lock to lock, if the mainshaft doesn't try to move up or down as you reach the lock postion of the wheel, you are there, if it tries to move, just slightly up or down, tighten the end plug another notch. That should have your steering adjusted with no slop, I used all new ball joints as well, it turns very easy, and the slightest movement of the wheel is transferred to the front wheels. I don't think I forgot any steps, and I did use the manual as a guide for adjusting mine, but I may have improvised on a set or two, but I couldn't be happier about the end result.