Just did the TRO with the new 1 ton rod ends and hoped that would tighten up my steering. Sadly it only marginally improved, so that has me looking at the box as being the main culprit for the slop.
Basically it is what I refer to as Hollywood steering.
Moving the wheel back and forth with no affect on turning.

It is a stock 74, 5 turn box.
Is there anyway to adjust the slop out of it?
Would I be better with a new/rebuilt box?
Which one? 3 turn, 5 turn, 4x4x2.
can I rebuild the box internals?

I kind of have the same issues and will be interested in what you find out. Viper sent me some good stuff about rebuilding it, but that appears to be over my head. Good luck. JP

There isn't much to wear out inside the box other than seals and o-rings. A rebuilt box is just going to have new seals and o-rings. If it isn't leaking and you have good power assist you should try adjusting the mesh load. I can't post the procedure here so I sent it to you in an email.

Make sure the box is tight to the frame and the pitman shaft isn't wobbling.

Brian, I'm with you, new TRO took about half of my slop out, I'll be checking over the rest of my system to look for more improvement. Not sure if your system has a rag joint, but if so check it as well.

has a rag and it is good. I guess I need to check the box to frame and pitman shaft.
Also I will try the mesh load adjustment. I read it but much of it doesnt make sense to me right now without looking at the truck.

I'll put in a vote for the 4x4x2 box. It takes some modification to install, but is more powerful than the stock box. I can turn my 35x13.5 tires on concrete with the end of my finger pressed against the face of the wheel. As with you, the new linkage took out about half of my slop, with the other half disappearing when I put in the new steering box. Ask Zoso about following me up a windy mountain road if you want another review. They're not super hard to make, but I got mine from cascadejohnson, who you may want to send a PM to. Have you seen this?:

http://www.wcb4x4.com/tech/diyrockcrawler.shtml

I also used BC Bronco's Frame Reinforcement Kit when mine went in.

http://www.bcbroncos.com/powersteering.html

Another good option is to send your current box off to someplace like West Texas Offroad, who reportedly do a stellar job. I'll let Viper speak for himself about whether he'd offer a similar service. I'm guessing you've already looked at your lower steering u-joint, this can be a common place for slop as well.

How much of the top adjustment screw (mesh screw)is sticking out? Do you have a lot of adjustment left? If it has not been adjusted, that may be your answer. Only adjust it in 1/4 turn increments, until slop is gone, as too much will cause you more problems.

And definitely take it around the block after each 1/4 adjustment. Too much tightening can cause steering boxes to not return to center, putting you in a perpetual turn. Not fun on the road.

Also check to make sure your track bar bushings are tight. I've had issues before and it was the slop in the track bar bushings that were causing it.