Front end rebuild - W115
 

So my first first - author technical paper was accepted for publication on Friday, and I rewarded myself by taking the weekend "off" to do a fairly intensive (in my view...) repair on the 300D. See pictures below!

Parts installing (All genuine MB):

115-330-16-75-MBZ : Lower control arm bushings (Done!)
115-330-17-75-MBZ : Upper control arm bushings (1/2 done!)
115-330-18-75-MBZ : Subframe bushings (Having difficulty...)
107-460-00-61-MBZ : Steering Box Seal Kit (Almost done ... see below.)

New parts! Love the look of these boxes together. Smells like money.
http://i137.photobucket.com/albums/q...pscwvtkior.jpg

Getting started. See the collapsed subframe mount from leaking power steering fluid and age.
http://i137.photobucket.com/albums/q...pssy2dxfm8.jpg

Steering box out:
http://i137.photobucket.com/albums/q...pszhvwkofa.jpg

Upper control arms bushings - here are the old ones:
http://i137.photobucket.com/albums/q...pshskrd1uo.jpg

New replacements. Quick job.
http://i137.photobucket.com/albums/q...psaiiafw4z.jpg

Lower control arm bushings. Worse condition than the uppers:
http://i137.photobucket.com/albums/q...psbiw7njpk.jpg

These are more difficult. I used a jack to lower the lower control arm bushings from the subframe. It's a bit precarious so I don't recommend someone unfamiliar with jack safety to attempt it.
http://i137.photobucket.com/albums/q...psrgsjmemc.jpg

The OTC front end kit was useful for the bushings.
http://i137.photobucket.com/albums/q...ps0gaukfhn.jpg

Next, the subframe bushings. I have put jackstands under the frame rails (around where driver's feet are, I don't know technical name). I then put a jack under the from subframe and loosened the bolts in the subframe bushings, then lowered the jack incrementally. The subframe dropped about a half inch but I can't get it to budge any further. It seems to me that all the weight of the engine would be pushing downwards to easily force this out, but that doesn't happen. If anyone knows of a particular bolt or thing I'm overlooking, a tip would be helpful.

Next, steering box rebuild.

David Petryk's page was helpful for the steering box. The W115 box is a bit different, e.g. it doesn't have the "valve cap" mentioned part 7.
How to reseal a MB steering gear

All went pretty smooth but I have issues with the power steering box seal kit I got from Pelican parts. I don't think I've had a single order from Pelican (out of a handful) where there wasn't some roll-your-eyes issue. I've complained on the phone and through emails but I feel as though it's fallen on deaf ears; maybe this public grievance will initiate some action to improve service quality. I got one of my control arm bushing kits from the dealership here in Atlanta instead, and the price was relatively good and the transaction was seamless. Anyway, back to the problems with the seal kit: First, it's missing the 2.25" inner diameter O-ring shown in the photo below (Taken from David's page).
http://www.davidpetryk.net/Mercedes/...s/image049.jpg

That same ring is also pictured in the following photo in the red box:
http://i137.photobucket.com/albums/q...pssclepolw.png

This missing ring really threw a hiccup in my repairs as I was hoping to have the box back up this evening. If anyone has a replacement sitting around and can ship immediately, I'll Paypal you $20 to avoid the hassle of going through Pelican. Must be power steering o - ring, not some generic one that can't hold up to power steering fluid.

I'm also suspicious if the "genuine MB" seal kit I got from Pelikan was in fact genuine. In the photo below it shows removal of a shaft seal (there are two of course). Both of the ones in my kit weren't marked with MB stars and appear much "lighter duty" than the original. As in the lip contacting the shaft is only half as wide. They are colored brown. I already installed them, but it would be good if someone could confirm my suspicion.

Shaft seals, showing original removal (also borrowed from David):
http://www.davidpetryk.net/Mercedes/...s/image035.jpg


Looking forward to comments/etc !

Warmth,
Henry C.

Did you undo the sway bar? Sometimes you might also need to undo the brake hose.

Oh, that's very helpful. I didn't unbolt the shocks, maybe that is why. We will see next weekend !

I did undo the sway bar. I will be careful with the brake hose - thank you -

-H

Congratulations on your accepted publication!

Why thank you! A good time to work on the car - if I really did a doozy, there would have been sufficient buffer for my spirits remained lifted. :)

H

As I found in your thread, the shock was the issue ! Subframe bushings are done, not too bad. Similar to upper/inner bushings, easier than the lowers.

Thanks again -
H

I'm now finished. Took me about 25-30 hours including clean-up.



Riddance below. See the transmission mount replacement too. I also had ordered a new shift linkage bushing, and surprise - surprise, Pelican parts sent me the incorrect part. [chuckles]

http://i137.photobucket.com/albums/q...psroqgfyn0.jpg


Pelican parts couldn't get a replacement genuine MB o-ring replacement for the missing one for at least another week, so they overnighted me a Febi kit - I used a single ring from that kit. Some old rings to show proof of work:

http://i137.photobucket.com/albums/q...ps1324kc8e.jpg


Here is me last Saturday. I had to get a 22mm socket from Ace hardware, when I stated my phone number for my Ace Rewards, I said '636- xxx - xxxx' but the cashier mistook it as '666 - ... '. I couldn't tell if it was just a verbal miscommunication or my devilish appearance...

http://i137.photobucket.com/albums/q...ps2p0ca7zk.jpg


Took vehicle for a spin last night. I lucked out and got the steering box on the correct spline with insignificant play. However, all the R and R of parts threw off the alignment, which I expected, so it's at the shop now waiting for an alignment.


Warmth,
Henry C.

Just curious, after the shower you took, are you and the wife still on speaking terms?:D

I'm guessing the "scrubbie" hanging from the shower pipe now resides in the dust bin.

I'm sensing topic(s) for the next tech paper...

I'd like to think I'm attractive in such a state. Scubbie is no more.

Ha - Saved us probably 3-5K - !

On a similar note, for those in Philly:

https://girlsautoclinic.com/repair-center/

https://www.phillymag.com/business/2017/10/02/patrice-banks-girls-auto-clinic-car-repair-mechanic/

Further - I did the shift bushings too. With all these new parts it feels like a new car! Upping insurance coverage from 10K to 15K now. I also rebuilt the fuel injectors with Monarks a couple months ago. Went from burning a quart of oil every 50 miles to less than a quart every two fill ups. More power, knock is gone, and I can drive > 70 on a flat highway. Hell yeah.

Warmth,
-H