D250 Steering rework

[Dennys502 246]

I decided its time to fix the steering on the D250. I had planned on converting it to power steering but don't have the time right now. Water had gotten into it and the side cover was cracked from the water freezing.

I sandblasted everything discovered that the shaft and worm gear were rusted bad. The races for the thrust bearings were almost completely gone. I ordered some new thrust bearings and machined the shaft for them.

I had to build a grinding fixture to smooth out the worm gear.

The shaft was too long for the steering wheel I decided to use so I cut about 3.25 inches off it. This required the shaft to have a new taper machined in it along with the splines and threaded end.

 

 

This is the shaft after sandblasting.

 

 

These are some of the pieces for the fixture I made for the chain saw sharpener to do the grinding on the steering worm.

 

 

Partially Assembled.

 

 

Set up for grinding.

 

 

Shaft all ground - the taper machined and end threaded.

 

 

Fixture set up to put splines on the shaft for steering wheel.

 

 

Putting the splines in.

 

 

Shaft all done ready to go back together.

 

 

Partially assembled.

 

 

Filled with oil and ready to go back in.

 

 

[DennisThornton 4,771]

I just saw pictures of how you did it and I'm just about as incapable as I was before!  Your fixtures pieces are rather impressive.  Looks like you took a lot of meat off the worm gear.  Now I sort of see how you are cutting the splines but how to you deal with the taper?

[Dennys502 246]

Yes unfortunately the pitting was real deep.

I tilted the head on the Mill 2 degrees to match the taper on the shaft.

 

 

[Pollack Pete 2,273]

So...........after all that work,how does the D-250 steer now??

[Dennys502 246]

Just like it did when it was new - like crap. But at least it steers. I put a smaller diameter steering wheel on - the same as the 5xi has so that doesn't help.

The steering boxes on these are one of the weak links. Eventually it will get power steering.

I'm spoiled by the power steering on the 5xi.

[WVHillbilly520H 10,376]

Another member on here used a GM electric power steering unit (like found on the Saturn/Chevy Cobalt ect) for the D series eliminating the need for hydraulic cylinders/lines, Jeff.