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Finally, after a long search for replacement parts and other delays, I reassembled the steering gear for my M38 with new bearings, bushings, and seal. I put just a little gear oil on the ball bearings, bushings and cam to lubricate things while making adjustments. I put a new gasket on, with clean surfaces on both the housing and the cover. Leaned it against the bench when I was done, and when I picked it up a couple hours later there was an oil puddle on the floor. It wasn't even on the chassis yet, or full of oil, and it was already leaking!

So, should I have put some gasket sealant on the mating surfaces? I have some Permatex aviation Form-A-Gasket #3 that seems like it might be the ticket.

Check the cover and box sealing surfaces with a straight edge first.

Make sure the pre_load adjuster is completely backed off.

If both are ok then try the permatex.

Yup, did both of those. On to the Permatex then . . .
Thanks.

Be sure to seal the two screws that go into the oil. The parts book also calls for flat copper washers to seal the screw heads.

TomM wrote:Be sure to seal the two screws that go into the oil. The parts book also calls for flat copper washers to seal the screw heads.

Good catch, Tom. I totally missed the fact the holes are open to the oil. That could very well be where mine is leaking.
I see the copper washer callout in the ORD 9 now. What is odd at first glance is that the part list ALSO calls out a lockwasher. Only the copper washer is shown in Fig. 14-3, which is a "late" (post-S/N 31337) steering gear, and only the lock washer is shown in Fig. 14-2, an "early" (pre-S/N 31337) steering gear. In many other cases the part list specifically refers to the version, but looks like they missed it on this one. My deduction is that they discovered the oil leaked around the screws on the early versions and switched to copper washers. Since I have a "late" M38 with correct "late" steering gear now, I'll do the same!