I know it’s hard to tell. I can move it 9-3 but not 12-6. The knock is from the gaiter area on the rack… I think.

Pulling on the rod, I can twist it pretty easy but can’t pull it without the wheel on.

Hard to tell from that. If you think it’s from the gaiter area then remove the gaiter, release it at the big end and pull it back. Are you sure you have eliminated track rod end, bottom ball joint and top mount. You really need someone else pulling the wheel about whilst your inspect each part for movement. Some gaiters are softer rubber than others. You might be able to squeeze the gaiter to feel the inner track rod end within the gaiter.   It does sound bad, like I think I might not want to use it until sorted

7 hours ago, isetta said:

Hard to tell from that. If you think it’s from the gaiter area then remove the gaiter, release it at the big end and pull it back. Are you sure you have eliminated track rod end, bottom ball joint and top mount. You really need someone else pulling the wheel about whilst your inspect each part for movement. Some gaiters are softer rubber than others. You might be able to squeeze the gaiter to feel the inner track rod end within the gaiter.   It does sound bad, like I think I might not want to use it until sorted

It’s been like it a while… but not this bad. It’s passed it’s Ford not without so much of an advisory in may. 

So, its been to 2 garages. Cant get in to a Ford main dealer for weeks!

They say its normal and that there's much less movement with the engine on. 

Have you got any side to side play when wiggling the wheels?

A lot of that play is you moving the whole steering rack, you can see the other wheel moving on the second video as you're doing it.

I doubt a main dealer would spot anything 2 independent garages can't.