How hard can it be to replace the box? I have a spare and my wifes needs to be replaced (leaking horribly). Any idea on how long it takes? Special tools?

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1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

I belive Whunter video taped that last fall at the Texas technical meet

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15 VW Passat TDI
00 E420
98 E300 DT
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97 S500
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86 Holden Jackaroo Turbo D
86 300SDL
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Url?

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Can you get away with unhooking the power steering parts and going manual? I was manual for a couple months, it's not that bad above 5mph

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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

If it's leaking only from the pitman arm shaft seal, you can replace that without dropping the box. I went a little further and replaced the o-rings in the lower pitman arm bearing assembly without pulling the box.

The only difficult part as I see it is aligning the box with the steering column coupling.

The only special tool when replacing the box is a good tie rod end puller. The drag link is always on the pitman arm but good. I'd be tempted to keep the pitman arm in the car but then you need an impact wrench to blast off the pitman arm nut without jamming the steering lock and a pitman arm puller.

Sixto
87 300D