The factory rack and pinion worked for 11 years without a problem. It was only replaced during a major suspension rebuild (Aerostar E-4WD) due to concerns about age and difficulty of replacement. The rebuilt racks from A1 Cardone, have failed twice in the past 2 years. The first rack leaked within the first week. The second lasted 18 months before leaking - both failed from end seal leaks. While the store warranty provides full replacement, the time, aggravation and alignment expenses are mounting.

I've replaced the R&P on other family Ford vehicles without similar failures and using the same rebuilder (A1 Cardone). Has anyone else had similar experiences with repeated failures?

Stepping back and pondering this situation, I have the following thoughts:

A.) This just a weird coincidence and the third rack will be successful
B.) There is something amiss with the PS pump (original) generating excessive pressures - although how this could be, I have not a clue.
C.) The other most recent rack replacement on a Taurus had a small check valve affair (in the fitting for the high pressure line, I think, but not 100% certain which line). This Aerostar rack does not seem to have one. When the racks have check valves, there is always a small NOTE tag attached telling the installer to be sure to remove the one from the old unit for re-use in the new, rebuilt unit. None of the three Aerostar racks have had this notification making me believe it is not used on these racks, but I am having some doubts, since the two racks are so similar in design and operation.

Can anyone offer any insight or advice on this? Thanks in advance.