Can anyone give me an indication how tight the modified mk sierra rack should be? At the moment with the car jacked up and column disconnected I can move it from lock to lock by pushing on the wheels (using both hands). I can also do it with one hand but is a bit of a struggle.

Is there a more "scientific" method by turning it with the pinion?

Or should i do an overhaul as a matter of course?

Cheers,

Chris.

Official way is with a spring balance and lever arm clamped on the pinion --- but never seen it done.

Your rack sounds as if the damper is set just a tiny bit of the tight side but not by very much --- the thing to watch for is if it is OK in the centre position but tight a full lock either way..
Racks wear more in the centre position so if the rack damper is ajusted too much it can be ok in the centre but too tight at the extremes.

ok thanks,

I've decided a strip down probably won't hurt anyway and at least i'll be able to check for any signs of wear too.

Just now need to find the correct grease for re-assembly.