So. Three weeks ago (ish) the airbag light came on and I parked the car in my garage until it was fixed. Last night the car left the garage. This is what happened in between:
1: The clock spring (or steering wheel module coil) was broken. I maybe kinda sorta broke the cables inside the clock spring, probably from being a bit too forceful when pulling the steering wheel off (oops)
I think it's broken.... by
Ben Stryker, on Flickr
2: The old knuckles were abused and mistreated, resulting in gouges and deformation inside the balljoint sockets
Old knuckle by
Ben Stryker, on Flickr
Old knuckle by
Ben Stryker, on Flickr
It's difficult to see, but there's a ridge in the socket where the old balljoints weren't fitting properly and had widened the hole to the point that I would have had to drill a new hole farther down the stud in order to hold the castle nut in place with a cotter pin. So I picked up a set of knuckles, along with a clock spring, cargo net, assorted little plastic nuts for the trunk, and an extra double din bezel for when I finally get a new head unit. (I tend to break interior pieces)
Junkyard parts are the best parts. by
Ben Stryker, on Flickr
(BTW, if anyone needs the extra trunk pieces, I can't fit anymore of them in my trunk so you're welcome to them)
3: The front LCA bushings had been rattling inside the subframe tabs for quite a while, I didn't have the T55 Torx driver that I needed when I installed the LCAs. Even though I got it tight, it wasn't tight enough to hold the center sleeve of the bushing between the tabs and a very slight amount of play turned into an annoying clunk and I had to fix it. So I went and bought the Moog Problem Solver spherical bushings and pressed those in, then used an 18" breaker bar with the T55 driver and a 36" breaker bar with a 21mm socket and full body wrenched those fukers tight.
New spherical bushings by
Ben Stryker, on Flickr
Full body as in feet on one bar, deadlifting the other bar. That seems to have fixed it.
4: Getting the old balljoints out was the worst part of it all. I had to drill out the heads of all 6 rivets, because an air chisel with a fresh bit couldn't get them off. It did eventually manage to get the rivets out... After almost 2 hours of full body lean into those damn things.
The last time I drilled out rivets it took less than half an hour to get all 6.
New balljoint by
Ben Stryker, on Flickr
But now they're bolted in, so replacement will be much easier next time.
And after 3 weeks, I finally have a working car.
Shiny! by
Ben Stryker, on Flickr
Still have things to fix, but that's just how it is when your daily driver is a 15 year old parts bin car. And I'm still never getting rid of it.