THE SHORT VERSION
Originally Posted by KerlyQ
Wow that is the identical spot mine is leaking too. Did you end up rebuilding it or just buy a new rack and pinion...I found a re-manufactured one close to home but doesn't come with any of the TRE's or bushings...So how did you approach this job? I want to try to rebuild mine but not sure if I need any special tools or not...What did you do?
That upper control valve seal (leaking in the OP pic) is the most difficult seal to replace in the entire rack. If it is to be replaced the whole rack might as well be resealed. This job is only for the well seasoned wrench. It requires a very clean work place, a press and 2 special tools. There is also a fair amount of "practices" and generic "standard shop procedures" involved.
This seal is relatively prone to failure due to a somewhat inadequate "dust cover", the rubber umbrella shaped thing at the top in the OP pic. The dust cover comes from the factory with a light coating of grease between it and the control valve housing. This grease attracts dirt and effectively contains the resultant sludge around and eventually contaminating the seal. It is a good practice to slide it up now and then and carefully wipe away the crud, don't wipe it into the seal.
The procedure in FSM is actually pretty good but can be intimidating. Read through it for a taste of what you are getting into.
Then there is the question, is it worth it? For 99% of folks, no. The condition of the rest of the rack is likely questionable. That and the year of production deserve a long hard look.
Here is a shot of the control valve internals. The seal in question is under the bearing (beyond the arrow). Both get pressed out together and back in separately. The bearing is reused. The octagonal brass piece is the tool used to R&R the lower seal carrier, required to get the valve assembly apart.
The seal carrier.
tool" in action, unscrewing the carrier.
The second "tool" needed works like a piston ring compressor on the 4 Teflon seal rings in the mid section of the valve. They get stretched out as they are installed and must be squeezed back to size. This is only needed if new rings are installed. I have the dimensions and several methods for making up these tools if there is interest.