A couple of days ago I installed a new steering box in the daughters 83 240D. That went pretty well. I was able to remove the pitman arm without to much trouble, using my cheapo Harbor Freight pitman arm remover (after a couple of days of soaking with PB Blaster, also had a O'reillys loaner just in case). Made the "special tool" to center the box for attachment to the pitman arm (M8 X 1.0 X 20MM bolt with the tip ground at a 45 degree angle MB tool 116 589 06 21 00). Attached the steering box to the frame with Locktight Blue. Reinstalled the pitman arm aligning the arm and box marks and all went well. Torqued to 200NM (147.5 FT LB)
Decided to change the fluid out from ATF to power steering fluid. Sucked out the reservoir, drained the box and then added PSF (power steering fluid) to the reservoir with the return line going to a container, used a 1/2 gallon of PSF, it really disappears fast with the engine running. Once the pink was gone we closed it up and cleaned everything with a good degreaser.

Be advised

If you get fluid on the accessory belts they will start to squeal and you'll think the fluid is ruining the power steering pump. So you remove the PSF and replace it with ATF. The belt will continue to squeal until you spray it with degreaser and it will stop.

So tomorrow we will remove the ATF again and install PSF. Get the car aligned, tires rotated and balanced, wash and wax it and make sure its ready to go to Texas A&M on the 21st.

Just one of those days.

Dave

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1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car