I needed to replace / repair the ESL in an 2008 E350. I have everything out of the way and I have complete access to the ESL...BUT...I can't turn the torx nut far enough to release the ESL and get it out. I assume this is because it is locked. I can't unlock it so how can I get it out ? (...it failed in the locked position) Thanks

 

You'll need to pull the column and drill/grind the torx screw out, or break the motor apart and turn the lock.

 

Yikes....

 

Here's a small tutorial on how to remove broken ESL, I took this column out from my car last summer when I got a working ESL w/column from wreckers.

There are four roll pins that hold the cover, which covers the worm gear:



Two on top, two on bottom:



I decided to tackle the ones that are slightly raised, but when the column is in the car you'll need to mess with the other two. I used just basic tools, round file and drill. I took off the material with a file from the raised parts, then drilled a hole to the corner:



Then I inserted screw driver to the hole and pried off the cover. Remove black plastic gear:



Then pull out the lock pin:



And then you can take off the winged torx screw and rest of the ESL:



Dremel or similar would be usefull tool for this job.
Quite easy job to do, took me about 10 minutes when the column was on the bench. In the car, same time with dremel but with the hand tools pain to do and time consuming as the lower roll pins have more material around them.

 

WOW....BRUTAL.....thanks.