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  #1  
Old 11-22-2004, 02:54 AM
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Join Date: Jan 2003
Location: Eastern NC
Posts: 329
Thumbs up w115 Steering coupling Finished

After changing the drivers side sub frame bushings( see thread at Started front end on 115 )
in the 76 240d I ran the lift up just to look at the steering coupler.

It was kind of tight to get to but with a 1/4 ratchet, a 2 inch extention and a 6mm allen wench socket I could get both screws out of the coupling, it would have been a little easier with a short piece of 1/2 pipe as an extention.
After rmoving both screws turn the coupling so you can spray white or lite colored paint in the split and on both shafts.
Three 15 mm (i think) bolts release the steering box and a short screw driver/prybar will ease it over and out of the coupling.
[I had also taken the 10 mm bolts off the collar around the base of the steering column inside the car behind the accelarator pedal while I was waiting for my brother in law to get there. I was thinking I could get to the coupling that way but b in law showed and we started on the sub frame. I don't know if the collar being loose helped or not but if you have trouble without loosing them you will know what to do.]
I could reach the coupling and just wiggled it off the shaft to the steering wheel. Put the new coupling back on the way the old came off if you want your steering wheel to be positioned like it was, it can only go back on this shaft correctly or 180 degrees off. Put the top screw in and hand tighten only.
By turning the tire, line the paint on the steering box shaft up with the bottom coupling split, with one person supporting the steering box and prying it toward the coupling and the other prying the front of the box toward the middle of the car and wiggling the coupling on to the shaft you should be able to get them started going together, you may need to tap lightly on the coupling to get it to slide on and once started and the steering box moves back over the frame lip into place you will need to pry the coupliing down onto the shaft still wiggling or tapping to help line it up.
Install second screw, tighten both, replace steering box bolts and tighten. {Replace collar inside if you had to loosen it.} Total time was 30 min or so. Hardest part was lining the coupling and the steering gear while prying on the box, mine ended up aprox two splines off but I need to work on my turn signals and I assume I can move the steering wheel a notch or two.
My old coupling was completely shot, no rubber left, just metal to metal and since it was newer than 1972 I could not just replace the bushings, I had to replace the entire coupling.
Car feels much better and no longer makes a clunking sound under dash when hitting bumps in a rough driveway.
I can't wait to feel the differance when I replace the other side sub frame bushings, the upper and lower control arm bushings and the shocks.
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1968 Torino GT fastback
1969 Ranchero
1970 Duetz Tractor Air-cooled diesel-rearend needed 4005 or 6
1974 240d 4-speed
1976 240d fresh paint
1978 300cd fresh paint and new rearwindshield rubber
1980 240d 4-speed-sold
1981 300d
1990 6.2 Suburban 194k-getting a 6.5 turbo
2002 Grasshopper Mower diesel
2008 Duramax Silverado
2015 VW Passat TDI
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  #2  
Old 11-22-2004, 03:11 AM
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Join Date: Jul 2002
Location: Raleigh, NC currently residing in KL, Malaysia
Posts: 460
Quote:
Car feels much better and no longer makes a clunking sound under dash when hitting bumps in a rough driveway.
I can't wait to feel the differance when I replace the other side sub frame bushings, the upper and lower control arm bushings and the shocks.
You will have a car that will outdo the ride/handling of most new cars
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  #3  
Old 11-22-2004, 08:20 AM
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Join Date: Jan 2003
Location: Dallas, TX
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On putting the new one on, did you put it on the box or steering shaft first? When I put mine on my box I couldn't get it to go on the shaft. When on the shaft, it's a pain also. Please do enlighten me. I did my 116 not too long ago and I am still suffering the consequence of a wheel off alignment. It's only a tooth, but it makes a pretty big difference at the wheel! I was running out of time so I just left it.
Thanks
David
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  #4  
Old 11-22-2004, 09:31 AM
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Join Date: Jan 2003
Location: Eastern NC
Posts: 329
I tried putting it on the steering box shaft first, too annoying.
Put it on the s wheel shaft first is easier but you are probably correct, if you lined the shaft on the box with the coupling first your steering wheel would have a better chance of being straight since the top side only goes on correct or 180 out.
I will be under the steering wheel working on turn signals so I will try to straighten the wheel then.
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Ncnetman
1968 Torino GT fastback
1969 Ranchero
1970 Duetz Tractor Air-cooled diesel-rearend needed 4005 or 6
1974 240d 4-speed
1976 240d fresh paint
1978 300cd fresh paint and new rearwindshield rubber
1980 240d 4-speed-sold
1981 300d
1990 6.2 Suburban 194k-getting a 6.5 turbo
2002 Grasshopper Mower diesel
2008 Duramax Silverado
2015 VW Passat TDI
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