I have been rebuilding my Rabbit power steering rack, just because, and I have everything out but the rack seal in the very middle. Small diameter hole, fairly large seal, up against a reduction in diameter in the housing. I have a HF seal remover set, with slide hammer. The largest seal remover that I can stuff through the seal (after some mods to get the next size up to fit) still will not expand far enough to get the seal out. I am stuck. I can make a seal remover from scratch, but that seems like a silly amount of work for the payoff. I can put the modded remover into a lather to give it a sharper shelf, which might work and might not. I can put it all back together as a core on a rebuilt unit, but that is throwing away the seal kit that is almost all installed. I can also run the rack non-power, which is how I have been running it, but I would rather finish "fixing it." The goal is to have power as an option if the uprated motor makes unpleasant amounts of torque steer.
The seal ID is about .85 (22mm or so) and I need to expand to something near 1.2 (32mm or so). This is two steps in the world of readily available seal pullers.
Does anybody have a trick I can try or the proper tool I can borrow? At this point, $100 (cheap if I could find it) for a tool that only does this one job is not really a good plan, since I am unlikely to be stupid enough to try this again.