Gave up and replaced the pump & high pressure hose, no more problems.
New pump came with an o-ring, and a plastic ring which didn't seem to fit anything. Didn't try the rack end of the hose, so maybe it goes there.
At any rate, glad to be putting this mess behind me.
Did you get it figured out? I'm in the same boat. Replaced the rack, pump & lines a coupe years ago and never could get it to seal right. Currently experimenting with different O-rings. A nylon washer didn't work.
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