2. Remove the unit from the car: We didn't remove the box as part of session, but the steps are simple to perform according to our experts. Separate the rod end from the pitman arm, unbolt the coupler from the steering shaft and unbolt the box from the left frame member in the engine compartment. You'll need to remove the pitman arm from the bottom using a suitable puller, but make sure you identify the alignment mark on the pitman arm (a punched dot) and the sector shaft (a line or a dot) so you can assemble it properly. If you can't find the marks, make your own before disassembly.

3. Disassemble the box: Drain the oil by removing the filler plug and turning the unit upside down. Release the lock nut on the adjustment screw on the top cover and back the adjuster out as far as it will go. Remove the bolts from the top plate. Remove the front plate. Finish backing out the adjuster and remove the top plate. With both covers removed, you should be able to take the box apart. Once apart, inspect the surfaces of the worm and sector gears for excessive wear and pitting. Replace with good used gears if necessary. If you want to dress up the box, go ahead and put a coat of paint on it. Don't paint the shaft right where it goes into the box -leave that little bit unpainted to prevent possible problems with the seal.

4. Reassemble the box: Assembly is the reverse of disassembly. Install the new parts in place of the old. Use a small (brass) hammer and a socket to tap the shaft seals in evenly. Lube the new bearings with Axle Grease or 80/90 Weight oil. We used the axle grease. Mount the pitman arm on the sector shaft, paying attention to the alignment marks. Once assembled, you must be able to turn the steering shaft fairly easily by hand. It's supposed to have resistance in the middle with no hang-ups to the right or left. Use the adjusting screw, the shims (Part# 659219-659224*) or the metal gaskets (Part# 656707-656710*) to increase or decrease play. (* no longer available from Volvo - thus the possible need for a spare box). You might enlist the help of a good mechanic like Bob Workman to help with this part. We used GaskaCinch for sealing the covers back on.