TOPIC: slack in teleflex steering

I have an older Teleflex rack and pinion steering system. Straight rack and the steering wheel turns about 1/8 rotation before the cable moves. It's snug at the motor end so the problem is in the rack somewhere. Before I take it apart is there anything I should be looking for? Maybe just a loose shim or something?

Sounds to me like you have a bad tooth on either the rack or the pinion, most likely the pinion. A broken tooth in the down position when the steering wheel is centered would give you that problem. You might consider changing out to a Teleflex cable model. They don't cost that much and they're very reliable.

I'll drop the pinion and take a look, only 4 bolts holding it together and it's easy to get to since all the seats are out of the boat. I'll probably fall asleep laying on my back under the dash
Not sure it's a bad tooth since even when the motor is full starboard or port the slack is still there. I'm thinking a shim or plastic/metal bushing is worn out and dropping the pinion shaft away from the rack a slight bit. I'll look at it next week. Got the Thompson rally tomorrow.

Two days later..... I pulled the flat rack away from the wheel shaft. The rack and pinion gears show no wear but there was dry dirty grease grinding in there. Found there is a nylon (?) bushing at the pinion end that showed some looseness around it's housing, probably worn from lack of lube. Cleaned it up and put a small piece of brass shim material between the bushing and the housing which moves the pinion gear closer to the rack gear for better engagement. Greased the pea out of it and put it back together. Seems to have improved the steering quite a bit with less slop.
End of story.

You are much like Sherlock Holmes getting to the answers of the problems! Well done again!