I rebuilt my Super Beetle steering box today.
Ordered new seals online. If anyone is wondering, the super beetle steering box oil seals are made by Federal Mogul, National Oil Seals. The sizes are listed below both in metric and american. You can search for them using the metric sizing. You can also get them from SKF at NAPA but you will need the part number.
28x40x7 (1.102"x1.575"x.276")
18x30x7 (.709"x1.181"x.276")
I filled the box up with transmission oil, Swepco 201, and so far no leaks.
I still can't remove all the play from the box. The tolerances seem to get tighter when the steering is dead center. So when the pitman arm is all the way left or right, there is play, but as you approach center, the play disappears. I inspected the worm gear and roller and they seemed in pretty good condition. There is no axial play in either of the shafts. I was wondering if this was a design in the gear box so that there is no play in the steering wheel when driving straight. Per the Bentley manual you are supposed to adjust the "worm to roller" lash when the wheels are turned at a 45 degree angle. If I adjust the lash so there is no play in the pitman arm at 45 degrees, the gear box locks up as it approaches center and I can't turn it. It is apparently supposed to be smooth throughout the rotation with no play in the pitman arm.
