I never want to work as a car mechanic...I'd want to commit suicide after the first day. So I'm finally diving into the car project; upgrading the front suspension. I've cleared my entire weekend schedule to do the work. Firstly, here's my garage and all the parts laid out:
After preparing the garage space, getting my tools ready, and getting the car on jackstands, I finally got to diagnosing and examining the entire front suspension.
The good news: thank GOD there's no damage to the lower control arms; no bushing damage, rubber looks great, boots are in good shape, nice and tight fit, arms straight, and no play at all. This is especially good given a lower control arm replacement would require that I remove the hub and the spindle...a good 4 hours of extra work just to do that! Also good are the front sway bar end-links; looks brand new! no play, no visible signs of wear, rubber looks firm and robust.
The bad news: both upper control arms on both sides are busted, boots exploded and metal to metal. Also, both tie rods are shot. The Left side is bent! I remember the exact moment it happened too....TURN 8 and 8a at Infineon with NTT's Brain in the passenger seat. Ever since, it's been getting worse. On fast right-handers which load and compress the drivers side suspension, I get a thumping and a hopping in the left front tire. Positively scary on TURN 3 at Thunderhill...hippity hopping all the way through! It's just been getting worse since.
Anywayz, here's the damage to the control arms and a comparison with a brand new one:
Here's my old blown out tie rod. I'm replacing them with uprated Bilstien tie rods...nice:
So I got to work on Friday night and it took me 2 hours to get the damn calipers off. Even after liberally Penetroling the bolts, removing the Two 21 MM holding the caliper to the spindle required the following: Get on the floor on my back and under the front bumper in order to access the breaker bar, brace my legs under the wheel-well to get maximum leverage, shimy the breaker in such a way that I had access to the handle, and then use all my levels to PUSH to get an additional 10 strength to break the nut off...AND I had only 1 inch of space for the breaker bar to swing. The caliper came off nicely afterwards...note to self: a floating rotor floats...as soon as I disconected the caliper, the 30lb rotor fell off narrowly missing my foot which would have surely severed my toes.
Here are my old rotors next to my new ones...mmmm, nice Zimmerman slotted.
The next day, I started work on removing the old upper control arms. Thanks to NTT's Brain and Rave-Boy for all their help...and of course to ThePerfectLine for all his tools. Rave-Boy particularly kicked ass, hung in there for 6 hours of busting knuckles. The down side to removing the front control arms was the necessity to remove the coil-overs and the accompanying mounting brackets...there was simply no other way, as NTT's Brain put it. So off they went.
Rave-Boy and I managed to get all the control arms off, pulled from it's pinch bolt, bushings compressed, and coil-overs back on. Had a minor complication with one of the new control arms but after 2 hours of literally banging on it with several types of hammers, it fit...hehe.
Taking a break to bathe and sleep. Will get back at it tomorrow to finish the job. Still got ta do the tie rods, replace the calipers, and put on new pads and rotors, which will be a breeze....I hope. I have a feeling I'll run into some problems,...it allwayz happens. Rave-Boy said he may return tomorrow and Tricked-Out WRX Man will swing by to drop off tools.
Will fill you in on the finish tomorrow.