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I've been putting this off because it hasn't leaked for a while, but it's back. It's leaking from the upper seal where the steering shaft enters the rack. Do I have any options other than replacing the whole rack?
Also, if replacement is the answer, can I install the sport rack with the higher speed ratio? I believe the Z51 package got this and it's like 2 turns lock to lock instead of about 2.75. They are the same price, but I wanted to know if any other parts would need repacing to accomodate the new rack.
It is possible to repair this leak without replacing the whole rack and pinion unit. Your Chevy dealer should have or be able to get what I believe is called a "stub shaft bearing kit". Was relatively inexpensive when I bought one three years ago. Comes with a new bearing and two seals that should solve the leak problem. You will need to remove the plastic boot over the lower joint and pull the steering shaft out - not too difficult and would probably make sense to scribe position of the shaft on both the upper and lower ends. When you have the steering shaft out, you will need to get the old seals out. I used a cordless screwdriver and a long drywall screw. Just drilled the screw through the seal between the stub shaft and the outer edge of the seal - the screw pulled the seal right out. Do the same with the second seal, fish the bearing out with a magnet, install the new bearing and seals and put it all back together. Nothing too complicated, just takes a while to pull the steering shaft, etc.