the main problem is the tie rods are not a few threads off theyre both almost to the end of their adjustment one very long and the other very short. thats the only way the wheels will sit straight at the center of travel in the steering box. do you think there could be something wrong internally in the box?
Almost sounds like the box case is physically wrong or it is shimmed sideways off of the subframe, or something is bent in that area. Is the box mounted flush up against its mounting surface?
Question to check something: Did you establish the box center turns to each end of the box's range with the steering linkage disconnected? That is the way it should be done, with the steering linkage off. If you find the center with the linkage all connected, then the steering stops out at the ends can throw off the # of steering box turns left and right. (These stops are designed to be more restrictive to keep the driver from jamming the box to it's stops.) A better way to confirm the steering box center is to tighten up the top adjustment on the box (try 1/4 turn and then 1/2 turn and so on 'til you can feel the center turning resistance) until you can feel the tightness at the center and use that peak turning resistance to determine the box center; afterwards, return the setting to how you found it originally.
If you do have the true center, then make a call to FirmFeel to quiz them about this and the box's center. Did you get the new pitman arm from them?
BTW, I can't see how the pitman arm can get clocked off 90 degrees; if it could, it would never return to straight ahead or only do so at one far end of the box's range.
