Personally, I think your torch has been overheated, and I wouldn't try to fire it up any more.
If there are internal leaks, you really should let Nortel look at it. If it is just a question of you having overheated the face, there is another option:
When Nortel introduced the Red Max, they offered a 'upgrade' kit for people that owned Major burners. This upgrade kit consists of the front piece to this torch and the red heat-sink body pieces. For less than $200, you can replace the whole head. Here's that kit on ABR's web site:
http://www.dichroicimagery.com/produ...oducts_id=2437
Malcolm