1989 240 Power Steering Gear Seal removal/replacement (passenger side)

[Flag240]

Hi,

The power steering fluid came pouring out of the passenger side boot while i was in New Mexico, en route to PA for the holidays. Made the rest of the drive without, and found an ebayer who had the right steering rack rebuild kit (It's the CAM rack). Anyway, finally got the car jacked up & removed the tie rod to get at the seal, and am stumped at how to remove it.

I've found other places on other sites where folks have discussed it, and even one that showed pictures of all the relevant pieces removed. I've been a DIYer on these cars for a long time, no formal training.

The pictures show the end of the rack with the tie rod removed; and the new seal, o-ring, and the white plastic bushing. I found an old diagram, that labeled the parts & showed the locking wire, the bushing, the o-ring, and the seal. Is it as simple as rotating the bushing with a pair of pliers, to bring the locking wire into a release position?

Bushing in place, passenger side, steering gear.jpg (203.5 KiB) Viewed 911 times

Bushing, o-rings, seal.jpg (70.76 KiB) Viewed 911 times

Wasn't sure which o-ring is called for, figured that would be clear by inspection once I got the bushing out. (For all i know, I'll need both - lots of parts in the kit.)

I've been searching pretty extensively online, but wind up finding info on how to replace the entire rack rather than just the seal. No info on how to get the bushing out.

I very much appreciate the help - I know for a bunch of you folks this is pretty basic stuff, but for someone like me, it's maddening. I've been driving 240s since 2006, and have learned a lot along the way. It's always humbling to take a stab at something new.

[mechanic]

Hello-
there isn't much on the web as to the schematic of the steering rack - I have rebuilt the rack on my V90 which is a TRW- there are two different types- but they have similarities.
The plastic bushing is held in place by a wire spring collar. when you remove that retainer, you need to use compressed air to push the plastic out- but be careful when you do this - aim it away from any person or animal and in an area where you can retrieve the seal cause it will come out with the bushing. you can wrap a towel or blanket or even aim into an box or bucket. also.
the piston will be removed by turning the gear as far as possible. you will have to remove the rack to replace the seal . make a note as to how this inner seal is installed. by using the inlet/outlet holes on the casing you will be able to see where to kine up the inner seal