Hi everyone, I'm looking for some post-mortem diagnosis of my steering box issue. I had the bolts shear off the box and the coupling break while I was driving the beast. Very scary. I want to see if anyone thinks using the wrong steering box caused this failure. Sounds obvious,but read on.


When I removed the box, I found unhardened, 7/16 corse threaded bolts holding the box to the frame. I bought a rebuilt box for my car and a new set of bolts. But once I went to swap the pitman arm, I could see that the rebuilt box was much different from the box I took out. I called the shop that rebuilds these boxes - apparently for almost everyone in the US. The guy at the shop had me read the casting numbers, and the box I took out of my car wasn't the right one. The correct casting number should begin with 14 but mine began with sixteen. The guy there said he used his reference system for 15 years with nary an error. So my car had wrong box. He said that the 14 series and 16 series weren't compatible. the newer 16 series had a different bolt pattern is different and the gearing ratio is different too. His advice was to put back a 16 series if that's what came out. He thought someone had switched front-ends of my car at some point.

I heli-coiled the mounting bores back to the proper metric size on the 16 series and put it back in. So do people think I'm courting another disaster by continuing to use the 16 series or is it a minor difference that isn't important as long as it bolted in w/the proper bolts?

__________________
1987 300TD; 166,000 mi/267151 Km - had to make room for the dog
1973 220D; mileage ??????
1978 300D; 178,000

The steering ratio is not so much a safety issue, within reason, as a preference one. Weather it fits and works without any binding or anything of the sort should be pretty obvious, I'd test fit the correct box if it bolts up, I like stuff like that original unless there is a compelling reason not. I'd also from all I've read really consider reinforcing the mounting area, and maybe even spot welding the box on. Stuff like that is downright scary.

__________________
One more Radar Lover gone...
1982 VW Caddy diesel 406K 1.9L AAZ
1994 E320 195K

If it mounts snugly without any gaps between the box and frame and you use the correct strength and length of bolts you should be fine. Be sure the bolts are long enough to get at least their diameter in thread depth. I would advise against trying to weld the box to the frame. I don't think you can get a good weld and if you try you will more likely weaken your frame, IMHO.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Don't weld the box to the frame. Welding will serve no purpose and will only weaken the frame at the weld site. Other than that I see no reason why a steering box that fits won't work.

__________________
"If it's in the newspaper it must be true." Dudley Do-Right

Not that it isn't overkill(which is consistently more fun), but I have a hard time believing a proper bit of weld and gusseting mayhaps wouldn't be a good long term thing for a documented week spot. The car is, after all, welded together mostly. I have a few rally car buddies that weld and gusset everything, it's like a religious mantra. I do believe a monkey with a torch could make bad things happen though.

__________________
One more Radar Lover gone...
1982 VW Caddy diesel 406K 1.9L AAZ
1994 E320 195K

If the pitman arm doesn't bind--which it probably won't if it had been driven like that----it willprovide OK service but my greatest concern would be that attachment and I would make darn sure that the mounting bolts have secure fit-even to the extent that they might be through-bolted right through the frame. And a reinforcing plate could be used on the nut side to insure there would be no warping. Steering boxes coming off the frame must be one of the most threatening breakdowns. Certainly a qualified hot-rodder friend could help. ( and what the others have said.)

Best wishes for a safe repair.

Sparky