It was indeed the track rod that I was thinking about. Plenty of posts have covered it well since I asked the question.

Craig,
The adjustment you did on the box to remove the free play ~ adjust the bolt on top of the box~ must have reduced the vertical movement, thats what it does. it lifts the shaft up so that the gear is tighter against the worm.
Remember you have to screw it out (opposite to most cars) to tighten it, as it lifts the shaft. My old 300D at 800k miles was so worn on the main shaft that you could wobble the input shaft yet by screwing that bolt out tight, it could be tightened.
Its a PITA to remove & replace the steering box, If you dont get the spline on the main (steering wheel) shaft right, your indicator lights will turn off at the wrong time.

Good luck with it!!

__________________
Grumpy Old Diesel Owners Club group

I no longer question authority, I annoy authority. More effect, less effort....

1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving

No problem, my Indy has ordered the part and I have an appointment for him to install it next week. I have no interest in replacing a steering box without a lift.

Even if it's not the source of the noise, it's really due for replacement anyway; it has a slight clunk when it hits the end of the free play at the center that I can't adjust out. I'll also have them do an alignment when they put it back together, I need it correct because I'm diving it to TX the following week.

He just got a face lift







I have a clunk thunk noise, almost sounds like it is in the door post area. think mine is the track mount. I have had it off and on for a while. first thought something was sliding around in the door pocket.

these are the original at 361K, so are due. everything else has been replaced at one time or other.

these cars will never wear out if enough new parts are thrown at them.


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

That's my approach.

How's your oil filter housing gasket? With the steering gear out, replacing the gasket is much less difficult.

If it's leaking, now's the time to get a new one in there.

Thanks for the suggestion. I actually had it replaced about a year ago when I put in a "new" engine, I had my shop replace all the seals that were easier with the engine out of the car.

Follow up: Replacing the steering box did get rid of the noise. The car is back with me and heading for TX tomorrow.

Bold move. I hope you had some solid test drives before doing a CO-TX drive on a new steering box. It's hot out there.

I drive that car all over the country, about 40-50k miles per year. The box has been working fine for a couple of days, not much to go wrong. I have to spend a week in the DFW area, then another week in the Houston area; not looking forward to the climate.

I'm still messing around with this steering box issue. Two weeks ago, my shop installed two different rebuilt steering boxes and it still doesn't feel quite right. I drove about 2000 miles on the second box (CO to TX and back) and it just feels a little too loose. I brought the car back this morning to try another box and replace a few components that are a tad worn. If that doesn't help, he will probably just rebuild a box himself. Sometimes it's a PITA to find good rebuilt parts.

Well, I finally have my steering back to normal. After trying three rebuilt steering boxes, my indy gave up and rebuilt one himself. My car now feels like new. I don't know what the parts supplier's problem was, but their boxes just seemed to have too much clearance.

Interesting story, glad your back on the road and like your car enough to do that much for her. How big a job was it for your indy with a lift and "know how" ?

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

I don't think swapping the box itself takes more than an hour or so, but then it had to be aligned (I also hade them replace some worn tie rods). The problem was that he ended up doing it three times. Now he's trying to figure out how much to charge me for this fiasco.

Looking at the rebuilding job in the shop manual, I think I would turn it over to my indy/friend. The box in my TD is leaking just a little but otherwise is nice an tight, steering wise. Thanks for the "heads up" on the REBUILT ones, which probably are not cheap. Where is your shop located ? This might be the time to get mine done

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"