Well it all boils down to a bad steering sector. Called the rebuilders and they didn't even argue the fact said another one will be on it's way. Makes me think AXRacer is right, throw a couple a seals in and call it a day. It's a real PIA to remove and replace the unit, headers have to come of etc. So I sure hope the next one is good! Told the rep and the rebuilders to PLEASE check the lash in the unit, yea like that's going to happen. Anyway, I'll post how it comes out when the new one comes. They said a week, must have to rebuild my core first, boy am I getting cynical!

 

Just to make it easier for others to follow along by using common terms: I think what you are calling a sector most call the steering gearbox, i.e. the entire cased unit that has an input from the steering column and an output to connect to and turn the wheels. A sector is a specific gear (actually a section of a gear hence the name) in the steering box on the output (or pitman) shaft and is a main part of what transfers the turning of the input shaft to the turning of the output shaft. You indeed may have a bad sector, but unless you are disassembling the gear box, you are changing the steering box not the sector. Here's an excellent video of the parts and operation of a power steering gearbox that is almost identical in design to the Toyota box:
When you tighten the lash, you push the sector gear teeth tighter against the piston rack teeth. There needs to be a tiny amount of space between the two for smooth operation and lubrication. If adjusted too tight the gears bind and causes excessive pressure and wear on the whole assembly.

 

Thanks for the lesson, always wondered how one of those things worked, until now it was FM. Steering sector is what I had to call it in order to get best results from Mr Google, always called it steering box or gear before. Thanks again.
-Doug

 

Update on the toyota steering, after installing three steering boxes finally got a good one! The truck steers beautifully and drives perfect. What a PIA!

 

I am waiting on delivery of a Lares rebuilt steering box. Who was the rebuilder of yours?