The distributor tube is the same one that's been installed since the system was new & working properly. I removed the resin, cleaned the tank & turbulator assy, inspected for cracks visually, reinserted the turbulator into the resin tank, covered the end of the tubing with a sandwich bag & rubber band & installed the new resin. I coated the top of the tube with silicon lubricant & screwed down the tank adapter. All seemed to go well, no visual concerns at all.
The turbulator had some resin in the secondary tube (the tube with the check valve at the top). I flushed out the resin, checked the balls (they moved freely in their bores), removed the bottom of the turbulator assy (the part that removes with the 2 screws) to check for cracks, etc, checked the rubber valve (not sure of it's name, it seems to shoot water from the bottom of the main tube into the secondary tube- I assume to create a vacuum to pull the resin into the secondary tube), it was flexible & returned to it's original position when "un-squeased.
I checked to see if the backwash was working by backlighting my resin tank (it's an opague tank) & watched the resin rise during the backwash cycle. The resin rises about an 1" to 1-1/2" during backwash. I've read where the resin doesn't rise much with a turbulator vs a plain distributor so I thought this rise was OK
I appreciate all the feedback, this thing is really getting me. The tech at softenerparts.com (not an advertisment, just for reference) is telling me that the timed brine rinse test isn't valid because the flow rate of the brine cycle is too slow & the pressure to weak to properly induce a leak if there was a problem present. I'm not challenging your diagnostic skills, just offering what the tech said- he may well be trying the CYA approach to his products since all rebuild parts were sourced from their site.
I assume you guys have experience with the timed brine test & it does in fact test the distributor tube for cracks & the associated o ring?
Also- you mentioned that maybe the turbulator is the source of my issues? How could that be- don't understand how?
Also- no resin balls in the aerators at the faucets.