2G Steering rack problem

[PlanZero]

Car is a 96 Tsi fwd. I've been having an annoying popping feel/sound when I go over bumpy roads and turning left on an incline. Of course, I replaced inner and outer tie rods, struts, checked all ball joints, subframe, sway bar and steering rack bushings, replaced motor mounts, etc. And the sound still persists. CV joints look OK, and I originally thought the shafts had a little too much in and out play, but when I compared them to my other Tsi they're the same.

Although its almost impossible to replicate the sound, today I had the suspension supported and someone turning the wheel, and I noticed a clicking sound from the passenger side of the steering rack where the tie rod connects. I removed the boot and there was some fluid accumulation. I assume a seal is bad. I am not losing any fluid as long as I've owned this car. Could this be the cause of my "suspension" noise and feel?
Also, I assume the only way to fix this is by replacing or rebuilding the rack. As long as I'm not losing fluid and she still handles/steers smoothly, should I even bother with the total PITA job of replacing the rack at this point?

 

[pauleyman]

How did you check said components? And if you had that much play in the rack it would show up in tire wear control issues etc. My guess is one of the items you checked is not fine. See first question.

 

[PlanZero]

Well, I used a ball joint separator on the lower arms and they were nice and stiff. Upper arms were the same. Inner and outer tie rods, struts, sway bar links, and all 4 mounts are new. I examined all the sway bar, steering rack, control arm and subframe bushings and they appear intact. I can feel it under the gas pedal, hence the reason I was guessing axles before. When I got the car it had horrendous hard shifting issues (automatic) which wound up just being the TPS. I was assuming many years of hard shifting put unnecessary wear on the axle splines but now I don't think that's the case. Needless to say, I've examined all these components several times and still can't pinpoint it.
Also, I did notice some uneven wear to the tires when I bought her, mainly the front inner treads were more worn, which shouldn't have happened with stock height and wheels and the alignment felt OK.