I installed a new steering gear on an '04 Rendezvous. After attaching the coupling to the the intermediate steering gear, I wound up with 1/2" more thread distance on one side than the other side to attach to the tie rods. (1/4" on drivers and 3/4" on passengers) Is that okay?

 

you will need to get an alignment . I counted the threads with a pencil when I installed the new rack and when I drove it to the alignment shop it was way off.

 

Roger that on alignment. Steering wheel can also be canted, off center when it should be straight other than making turns.