To answer your question, IMO, the wheel should fit the hub pretty well. You dont want the wheel to rely on the lugs alone. You say you have already checked the wheels for balance, or have had them balanced.
Couple questions for you......do your alignment specs match what the rack-n-pinion manufacturer suggested? Sometimes they suggest a slight amount of toe in.
How new is the rack-n-pinion? When rack-n-pinion kits for our cars first came out not everybody used splined shafts to tie into the knuckles and or u-joint connections. I would check and see if the rack unit isn't loosening up somewhere.
Are you tightening the wheel lugs with a torque wrench and/or checking to see if your lugs are backing off?
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Gaetano Cosentino
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