Steering rack refurb - how do I remove the inner seal?

[An Marcach]

I've finally got my steering rack complete dismantled and the next job is new seals.

My first question is how do I remove the old inner seal without damaging the casting and more importantly how do I fit tne new seal without damaging the seal ???

The second question is about the seal size, as far as I can make out off the old (outer) seal its a 25 x 39 x 9 but can anyone confirm this and also I'm guessing the inner seal is the same size but does anyone know for sure?

[An Marcach]

Anyone .... ?

[mikesr]

You need to make a seal removal tool. Basically a piece of wood with a screw through it at right angles. Saw the head off the screw so that it is just too long to fit inside the seal you took out of the cap. (Yes they are the same size)
Then put the casting in the oven so its nice and hot - I think I used gas mark 6.

Carefully push the screw into the inside of the seal. It should catch the rubber as you try to turn it and because the casting is good and hot and has expanded it doesn't need much effort to twist the seal out of the seating.

Heating again (but not as hot) before fitting and using a correctly sized socket - just a bit smaller than the seal OD - allows you to tap it in without damage.

[An Marcach]

Thanks