The AIM for a 69 talks about putting spacers between the rag joint and the end of the steering column before tightening rag joint bolts all the way. Are you guys doing that? What are you using for spacers?
Thanks,
John

The spacers prevent the rubber from being crushed and torn again, If you buy an after market kit it will come with bolts with an extended shoulder, these are used in place of the spacers.

If the assembly plant needed the spacers to insure good alignment of the steering column to steering gear, it follows that it might be helpful for you to create your own if the special plastic spacers didn’t come with your new replacement part.
http://i2.photobucket.com/albums/y38/JIML82/FlesCplgSpacerPic-1.jpg
PREPARING THE FLEXIBLE COUPLING FOR INSTALLATION
I suggest that you use a roll of ½ inch wide masking tape and wrap each of the pins until you have about a 9/16 inch diameter roll of tape (about 1/8 inch thick on a side). Now when you bolt the column flange to the gear flange and coupling assembly, the pins will be held rigidly central in the window slots in the column flange. You can dig the masking tape off the pins when your installation is complete

IMPORTANT
The vehicle should be on its wheels when reinstalling the steering column.
This is what can happen to the flexible coupling if the steering column shaft is not aligned to the steering gear input shaft. Note the wear on the inside edge of the stop pin on the left.

http://i2.photobucket.com/albums/y38/JIML82/FlexCplgWornStopPins.jpg

To check the alignment, there should be equal gaps from the stop pin to the steering column flange cutouts. Check both pins. Now rotated your steering wheel one quarter turn. Check the gaps in this position. If the gaps are equal in both steering wheel positions, recheck that you have tightened all fasteners to their proper torque. Then you are done.