Took the jeep back to the dealer service that replaced the column. The binding is gone, but now there is that 1"+ of play in the gear box. The "service manager" is saying that he thinks everything is "tight".
I told the guy there that I have been communicating with throughout that I have put a ton of work into that front end and there was no play whatsoever pre-accident, I would have noticed over an inch.
I swear they see an older jeep and figure that shit is just worn out, as though someone who's worked on the jeep over a decade would be oblivious to it's state.
They are now telling me that it was a re-manufactured box they put in. One with a ton of rust on it.
Ugh this sucks man.
Unfortunately it doesn't surprise me with a dealership. Most dealerships educate their techs on the vehicles that are currently sitting on the lot and those still under warranty, that's it. I'm sure something as old as a TJ is foreign to them, you might as well be bringing something to them from another brand unless there is a really seasoned tech at the dealership familiar with them. I know it's already deep into this, but maybe something like a 4x4 or offroad shop would have better advice? This is a long time to be out a vehicle for them to put a used steering box in it. I mean I could've done that in the driveway. Maybe talk to the insurance since they are supposed to make you whole, and have them cover the cost of a new steering box but agree to cover the cost to have it installed somewhere or yourself?
I've been down this road when I was an insurance adjuster with older vehicles, I had one car back to a dealership like 4 or 5 times before finally I talked to the customer and said we need to figure something else out because clearly the shop doesn't know what they are doing, and we ended up bringing the car to an independent that specialized in that brand.