So in Jan 2014 I replaced a rack and pinion and p/* pump(Olds Alero 2003 ) and all was well til November 2015 when it blew out on the driver'* side seal. And it ran the pump dry so that went out as well. So both being under warranty I replaced them both, literally boiled the reservoir clean, bought new hoses, and a new filter. I connected every thing up and ran the pump and lines through the filter only for about 30 minutes. There was no way to mount the filter permanently as there just was no space for it. I then connected the lines to the new rack and pinion and purged the rack as instructed on the Cardone literature and web site. Last Friday My step son (who drives the car) pulls in the drive stating the steering is blown out again and there is a puddle under the driver'* side seal on the rack and pinion once again. What am I doing wrong?

Wow....never heard of that.....I mean, seals can leak, but they are gradual, over time.....they don't just blow out......

I don't think you did anything wrong......sounds like a bad rack....let'* face it, most racks are rebuilds.....you are at the mercy of those doing the work, on them.....

When I took the lid off the power steering pump reservoir it was under pressure and it was about 1/8 - 1/4 full of fluid. If that makes a difference.

That means nothing....all it means is you have a leak somewhere......

With the level that low, that pump should have been making all kinds of noise, especially on turns, due to aeration.....your son, feeling the steering going bad on him, should have checked the level in the reservoir and immediately added PS fluid, to protect the pump......

First you have to make sure it'* the seal that is leaking on that side , and not either of the two lines that connect to the rack on that side.......

A rack that leaks from a seal in 4 months? I still question the quality of the rack....

You should add fluid until full......with engine off and front end jacked up, rotate steering wheel to extreme left and right 10X'*, to remove air......then check level and add if necessary.....drop vehicle and run the engine while rotating the wheel left and right, to further remove air.......then look to verify, if indeed, the fluid is coming from the bellows on that side, or elsewhere....