I found this thread and proceeded to completely disassemble my PJ Grady - rebuilt rack today. It started by noticing my passenger side boot had a tear on the top of it (so oil can't come out), so I ordered a set of new boots from DMCMW. I did the driver side first, no big deal but it was pretty hard to stretch the boot over the rack end. Finally got it. Then did the passenger side. Well that side was more rotten so it came off the tie rod in two pieces, and I found a fair amount of metallic debris in the boot that appeared to at one time make a round shape. Also some metal junk at the end of the rack tube. I then found the rack had enough play in it where I could move it left - right - up - down. Further investigation into this thread and I found the metal crap must have been, at one time, my passenger side end bushing because there was nothing remaining there. I assume Grady is/ was using a metal bush at one time during my rebuild, which would have been like 15 years ago.
Finding the debris made me worried about more metal crap inside the tube so I proceeded to remove the whole rack. In addition to the shop manual instructions I had to loosen the top U-joint as well to get enough movement of the intermediate shaft to slip the bottom U-joint off the pinion. Thank God the last time I was in here I put a lot of antisieze all over these threads. They moved pretty easily once the lock screws were removed from the U-joints ( I have Darryl Tinnerstedt's U-joints)
In taking the rack apart, I also found a small stainless washer under the spring that tensions the oil cap. That is not mentioned in this guide It is between the spring and the white plastic spring holder.
My white plastic spring-holder under the oil cap is different - it comes in from INSIDE the tube and has a flat lip that has the same radius as the tube. Therefore it's impossible to remove the white piece after removing the oil cap - it has to come out after the rack has slid out of the tube.
Also, not sure if this is typical, but there is a very thin washer under my large inner race (where the inner race is butted up into the rack. The washer has been drilled sideways a bit so the hole is oblong. I found this extremely helpful in removing my outer race from the bottom of the tube because I was able to get a hook tool into the part of the oblong hole that gets under the race and pry upward to get the race out. Once I had it loose, I turned the rack over and set the pinion side onto a piece of wood while tapping on the flat side of the pinon holder with a plastic mallet. This loosened the inner race so I could grab it and pull it out.
So, now I just need to get a new passenger side bushing (I am checking with Grady and if he doesn't have it, I see Josh sells it) and I can put it back together and once again have a perfect steering rack.