300 TDi Steering Column repair

[StevenA]

Since I bought my 300Tdi, it has always had an annoying knock in the steering column when switching from turning right to left or vice versa. It was minor, but as felt through the steering wheel, unsettling. It was definitely in the upper steering column, and having passed 2 MOT's, obviously not an issue for the testers.

After much searching, the only reference I found to steering column repair, was for defenders, or for a 200tdi, and this referred to changing sheer pins which I did not want to do for safety. Resigned to changing it, I found that unfortunately they are no longer available, so I pulled one from a wrecked Disco that had been hit side on, after verifying that it did not have the problem.

After changing it I checked the old one, and here are my findings which may be of use to someone else (sorry no photos)

The column is actually very repairable.

The actual shaft is in 3 parts, with a UJ between the top (steering wheel end) two. The bottom two sections are joined by two injected nylon sheer pins. These sections are ovoid with two flats, and the top most part fits inside the lower one, the shape giving rotational fit, and the sheer pins giving longitudinal fit. The rotational fit was where the problem was, as the outer part is lightly crimped on the inner part at the very end, and this one was just not crimped enough - there was no wear or rust, just a weak crimp - 2 minutes in the vice with a bit of pressure and good as new!

To take apart, simply undo the lower (exposed) UJ bolt and gently pull the bottom 2 parts out as one. There is a roller bearing in the bottom that can now be changed if needed.

The top part is held by a badly fitting circlip, and can be pulled through its bearing, once this is removed. This allows access to the top UJ bolt and separation of that from the shaft. The top bearing could now be also changed.

None of this places any stress on the nylon sheer pins between the lower two parts, which there is no reason to touch or disassemble.

So this unserviceable part is actually very serviceable and without compromising its safety. I did not have to change either of the bearings or the UJ, but the bearings are probably easily found. The UJ is probably harder to replace, but is well protected and so probably rarely goes.

Hope this may be of use to someone with similar problems. Usual disclaimer - servicing unservicable parts, particularly on the steering, has to be done with care and attention to detail. It worked for me but I make no guarantees or recommendations to anyone else and following these instructions is at your own risk.