**Disclaimer - despite multiple threats – no bodies were killed, mutilated or hidden during this process.**
A few of you already know – well, in all honesty, quite a few – that Jay and I performed a vehicle repair/replacement on his truck last week. If you didn’t see the Facebook rants or hear me hollerin’ outright…I will fill you in on how things went down.
A couple of weeks back, we decided that we had pushed our luck with the worn-out tires on our vehicles and committed to the investment of replacing 3 full sets of rubber. We took the two daily driver vehicles for post-tire alignments. Jay’s truck came back with bad news. An alignment would be pointless without the replacement of two steering components – the idler arm and the pitman arm. For those of my readers that are less mechanically inclined or don’t really give a hoot about car parts – those are two parts that link the relay rod (long rod with tie-rod ends that connect to the swing arm) to the steering mechanism or steering box/gear. They allow the wheels to move in the corresponding direction of the steering wheel based on pivot and ratio. The dealer based repairs were quoted, with alignment, at over $600. Jay declined and at some point (though not at my insistence - despite his claim to the contrary) decided that he would replace these parts himself. He was convinced that the dealership was trying to screw him and that the parts did not actually need to be replaced. I explained that they really didn’t have any reason or desire to work on a ’99 Chevy truck at the Nissan shop and that if they had done the alignment without the repair and the tires wore out – THEN they would have screwed you.
While in all reality this job should have been a fairly easy one, that is NEVER the case with anything we work on – for a variety of reasons. Jay and I are like night and day, ying and yang, and oil and water – especially when it comes to vehicle repair. I have sworn (and cussed) many times that I would never work under the hood, undercarriage, or any other part or portion of a vehicle with him. Generally, we see things differently and in most cases those opposing personality factors are the “opposites attract” glue that bind us together…except with car repair. And with a variety of relatively hefty, sometimes sharp tools at my disposal – I have often feared for his safety.
I try to take a more organized, thought induced approach at things, whereas Jay, on the other hand, is a Fly-by-the-seat-of your-britches-you-read-the-instructions-it’s-all-your-fault kind of guy. So when he called me late on Thursday afternoon to ask if he should run and pick up the parts….I should have immediately called Travelocity and booked my room. I didn’t want to get involved – but I knew that at some point that was not going to be an option. I am the wingman. I am the navigator. I am the whipping-boy. I support (and often influence – but it was my desperate intent to not influence the decision to do the repairs at home) when he decides to take on a task that I know will be painful, if even only for me. It’s who I am.
My honest hope was that purchasing the parts was the only task on hand for that Thursday; but alas, when I pulled in the drive not only was the vehicle – a 1999 Chevy K1500 extended cab 4 wheel drive truck – up on stands with the wheels off already…but it was parked in front of the other vehicle that we could have been using for transportation during the fiasco…er, I mean, project. Score one for frustrated. And rather than do an inventory of what tools we would require and verify that they were present and accounted for…he started the dismantle with less than ideal options. Score two for frustrated.
The pitman arm had a large nut (not as big as the one wrenching on it mind you) that was on there pretty hard. After soaking it with some penetrating oil and fighting with the clearance and room to move, he was able to add it to the pile of random nuts and bolts that had been removed from the various working mechanisms of the vehicle. I was sticking to my guns and staying out from under the vehicle – a decision that ultimately cost us many hours of disassembly and re-assembly because my familiarity with what had already been dismantled was nil and my learning curve was arching pretty quick. I have two, well three actually, distinct advantages when it comes to working on cars – 1) I have a fairly strong mechanical inclination, the stuff just makes sense to me (I thank my Dad and my Grandfathers for those genetics), 2) I enjoy working on stuff and especially with tools (anyone who knows me, knows I am a tool whore – screw the jewelry – keep me away from Sears!) and 3) my hands are considerably smaller than a mans (as is my general frame, so popping my head up under a car is as easy as a prairie dog in a burrow).
After much anger, impatience, insult, penetrating oil and brute force from Jay and much patience, tongue biting, hypothermia and teeth grinding from me – it was decided we were at a standstill and that job would have to resume the next evening after work. It was 10:30pm. All of our metric tools were at Jay’s job site (yes, this is a Chevy – no it does not use the Standard System of Measurement) with the exception of a few sockets. We were cold, tired and frustrated. End Day 1…
The next day was Abby’s first day of Spring Break and I had scheduled it off. I opted to skip working on the vehicle and cleaned the house and took her to the park instead. Also needed to mow – but was planning to pull that off while he was “working” on the car to distance myself from the thrown tools. We had gotten up early to take him to work and were planning our day around the 3:30pm pick up. It was still up in the air whether he would have to work Saturday or not - so there was hope that I would have another 8 to 10 hours of free time that did not include the Angry Mechanic. When I picked him up, we loaded the tools, covered the seat and headed back to the land of shade tree mechanic. Once home, I changed into my “work clothes” and got permission to mow while he started back up on the repair. I should have known better…every time I stopped to empty the bagger - I had to fetch a tool, read a page, grab this, oil that…. Good thing I can multi-task or at the very least not lose track of what else I am doing. At one point, we realized that a different type of puller was needed and therefore part runner was added to my occupational list. I ended up buying a new set of metric wrenches and a set of heavy-duty jack stands – the wobble of him banging on stuff was nerve-wrecking.
Again for those who are not familiar with the mechanical working of a vehicle – in order for moving metal parts to remain moving, whether pivotal or rotational or otherwise, lubrication is required. For areas where contact with air, water, salt, dirt and various other elements occurs, the lubricant is known as GREASE. Grease is thick (varies as to its purpose), it has nearly zero viscosity (or flow) at normal operating temperatures and smells. It is generally contained in rubber boots, gaskets and reservoirs, but on a vehicle with over 200k miles most of those are damaged or gone. This means that the grease has now mixed with the variety of those elements and the resulting sludge is…well, sludge. Thick, black, sticky, smelly sludge. For those of you who know me…I am kind of anal. You can imagine the teeth grinding involved when all of MY tools were now covered in this sludge. I kept myself busy and quiet by repeatedly wiping down the tools and handing them back to him like a surgical tech. I was even wearing latex gloves, because I learned the hard way that Purple Power de-greaser is far more effective on the fatty content of your skin than it is the grime from the vehicle. After five hours of zero progress, multiple threats to go buy a brand NEW truck and let this one rust to nothing in the drive and me with a bloody tongue from biting through it…we called it a day. End Day 2 – Friday.
Up and at ‘em early Saturday (he wasn’t required to work overtime – which was met with mixed emotion by me) we got back into the “work clothes” (mine of which were now completely trashed) and headed out to get started. It was FREEZING. It was overcast, cold and windy. Mind you, had he opted to move the Miata out of the garage BEFORE he put the truck on the stands…he would have also had the option of pulling it into the garage. But I digress…. We had a heater going, a halogen lamp that was hot enough to cook on and multiple layers of clothes. As the repairs started with very little progress, he started to threaten to take parts off – that in my opinion were not required and would pose not only more work, but additional cost. I had managed to stay out from under it up to this point…but it wasn’t looking like that was an option any longer. It was time for an intervention. Needed to break the dismantle addiction. It was looking like I was a bit too late – the passenger side tie-rod end had already been broken loose…I needed to work fast. There was incoherent mumblings of stabilizer bars and rounded bolts – I was running out of time.
I crawled under the truck and did a quick survey of the dama….I mean inter-workings. The nut was off the relay rod at the tie-rod end – check, the nut was off the pitman arm – check, the pitman arm was removed from the relay rod – check, the nut was off the idler arm – check, idler arm removed from relay rod – check, tie-rod end was broken free at the swing arm on the passenger side – check. We used the two jaw puller we had rented to pop the idler arm off and I managed to maneuver that out of the tight location it was nestled – the response from Jay was less than complimentary but it was out either way. He wanted to pull the relay rod completely out from under the truck (I was opposed - but we chose our battles) so I broke the tie-rod end loose from the driver side swing arm and we slid it out of there. Where Jay promptly, though rather pointlessly, started cleaning it with a wire wheel. More tongue biting and teeth grinding on my part. So after he realized he had been “squirreled” and returned back to the task at hand – he started trying to break the pitman arm free from the Steering box spline (toothed shaft that interlocks with the pitman arm by sliding into the matching toothed collar). Ideally, we would have used the two jaw puller for this task as well, but we were tight for room so Jay attempted to use the wedge (a fork like device of hardened steel that is used in combination with a hammer to drive two parts away from one another) to beat the pitman arm down off the spline. After an hour of banging, I started recommending cutting the pitman arm off. Banging continued, interlaced with complaints, curses, threats and frustration. After about eight hours, and me having finally gotten interactive, I declared that despite the fact that I was already freezing – I would be getting a Dairy Queen Blizzard and that I didn’t care what he said. At that, he recommended that we start cleaning up. Had I known how easy it would be to get him to quit for the day, we would have been eating DQ every night of the project! End Day 3 – Saturday.
It rained, or rather stormed, Saturday night and left us with a wet surface to start our repairs out on, on Sunday. Picking up and dragging out tools everyday was getting kind of old and by the look of it – we were nowhere near done. So, bright and early, the banging resumed, as did the cussing and carrying on. At 11am I recommended he take a break ( I was starting to lose my patience with his lack of patience) and go watch the Supercross race. It would give me an hour to research the pitman arm and him some time to decompress. I read forum after forum and sent a plea out on Facebook for salvation. Everything I was reading said the same thing I had been saying to him….heat it or cut it. Apparently, the pitman arms on these trucks are tight – actually compressed on at factory and no one seemed to have an easy time with them - at least not on the Internet. My friends Kally and Linda Arbre got back to me and validated everything I had been thinking up to that point (And Linda has changed out some of these) so while he was still in the house, I broke out the cutting tools.
I opted for the Dremel with a regular cutting wheel. There wasn’t really enough safe clearance for the 4 1/2 inch grinder with a cut off wheel and I didn’t dare want to nick a brake or power steering line. Just as I was getting ready to cut it up….Jay came out and said he would do it. Gulp. All I could imagine was a nick in the spline, or me turning my back and him cutting off the sway bar. The spline damage was circumvented by the use of the Dremel, because the cutting wheel depth prevented that from happening. Shwew. After a few minutes and one swap of the cutting wheel, we were ready to try banging it off again. Bang, bang, bang….off. Well, cutting it off would have saved us approximately 11 hours. The bottom of the steering box was beat to crap…but the spline appeared to be undamaged. I say appeared and you will see why in a minute.
It was now time to start the reverse of our process…we decided to focus on the pitman arm nut because we already realized that the idler arm would require two people and some compression. The pitman arm seemed more straight forward – line up arm on spline in the orientation it was removed and tighten nut. Um, yeah…..riiiiiiight. First of all, for the record, the nut on the spline is big-ass (yes, it is an engineering term). It measured out at a 33mm, based on the adjustment I read on the crescent (our biggest adjustable or fixed wrench). The crescent didn’t have a slim enough profile to get into the space available so we could get solid torsion on the nut and rounding the nut was definitely going to be both a problem and an issue. I left to try to hunt down a 33mm wrench or socket. Sears – nope, Lowes – nope, Farm & Fleet – nope, Autozone - sorta (it was an axle nut socket which was too large to make the clearance). Dead end. We took the steering box off the frame, tried it from several directions with the crescent. Took off the pitman arm, checked the spline. Checked the threads. It wasn’t moving up the spline with the tools we had – it wasn’t supposed to be this hard, but we figured it was just a lack of leverage. The right tool would make all the difference, right? We were going to have to check some of the speciality stores tomorrow – or rather, I was. End Day 4 – Sunday.
I took my lunch break and got to do what I love to do most…tool shop! And it would be funny if there was some sarcasm there – but remember I am a tool whore! I went to Fastenal, which tends to cater to commercial workers. I was confident going in that this would be a one stop errand for me…guess I forgot what we were doing. I search the wall of wrenches – 27mm, 30mm, 32mm, 41mm, 45mm, 48mm…. What the….????? I looked again. I looked at the tags on the hooks. Nope. 33mm is NOT there. Checked the sockets (which were not the preferred tool of choice) there was a spot, but it was empty. I asked the lady at the desk. She confirmed no 33mm wrench available to her and the socket would be a 1-2 day delay. She recommended her competitors – one of which I would have rather given my left foot than have to deal with. I was stuck…so much for one stop errand. I hit up Grainger – same thing. Next it was the C&H Tools – my least favorite tool store in Peoria. The owner is a self-absorbed creep, he marks up all his stock 10-20% so he can look like a hero when he gives you a discount of…yup you guessed it – 10-20% and he drives around to all the job sites in this OBNOXIOUS truck with a ridiculous lift kit on it and really ugly (and older than should be participating) chicks in the bed of it – to throw out T-shirts and water bottles. Wrong on so many levels. And as expected – no 33mm wrench OR socket. (At least I didn’t have to compromise myself and give him any of my hard-earned money.) So on my way back to work – empty-handed (didn’t even buy myself a tool – amazing) I took a chance and called my dad to see if he happened to have the elusive 33mm wrench. I knew it was a long shot because my Dad is not shy about telling you his opinion about Metric measurement. He took a look and his biggest was 32mm but he offered to mill it out to 33mm. We might be on our way. I thanked him and told him we would be over after I picked up Jay from work.
Since I had been venting on Facebook and asking everyone I knew for tips or suggestions, my brother was aware of the aggravation we were enduring. He offered to swing by and see if there was something that we were missing – that extra set of less-tired eyes. Jay and I ran up to dad’s and grabbed the wrench and set out to finish this job once and for all. Bob and Jay started working that nut over. Pushing, pulling, leveraging, and …. stretching the newly milled wrench to approximately – 36mm. FAIL. Bob mentioned that maybe the AutoZone part we had was defective or not set to the proper taper because it seemed to be going on a lot harder than it should be or that maybe we should try an impact gun and socket. So we loaded up to go get his gun and a 33mm axle nut socket. After all, we were running out of options for tools that were 33mm and the air tool would certainly bring it home. Back at the house – and nope. Zero progress. More threats of new truck purchase and of cutting off of truck parts (sway bar, brackets,etc…) Additional thoughts in my head of best places to hide body.
I grabbed the receipt for the part and noticed that they had not specified the year, make or model for the part, so I decided to call them and verify that the part they sold us – was, in fact, the correct one for the truck. This created a new irritation. When I called AutoZone and asked to verify a part number, the clerk that finally took the call asked the year, make, and model and then proceeded to give me the price of the part. I explained that I needed the MODEL number. His response? “Why, are you going to go buy it somewhere else?” I contained my anger just long enough to explain that we were trying to make certain they gave us the right part that was not installing correctly…. he verified the part number and I hung up. From there, I lost it. I called O’Reilly (we had been in there earlier to get the socket) to see if they had what we needed in stock and they had a MOOG part for a bit more, but that part seemed to be better received on the forums. I told Jay to knock that one off the spline and that we were going to shove it up AutoZone’s ass, along with all the rented tools we had and get the MOOG part. We would not be giving AutoZone anymore of our hard-earned money after the insults. He agreed. He did. And we returned the stuff and got what we needed. At this point it was 9pm. End Day 5 – Monday.
Let’s point out that it has been five days of repair and I am exhausted and I have class and homework and a quiz that I have not even begun to study for….
Tuesday evening and I help minimally, as Jay attempts to put the NEW part on and ends up with the same amount of progress up the spline even with the air tools. At this point, he is beyond frustrated (not good for the whipping-boy) and I have class, which means he will be under a truck on jacks - alone. This makes me nervous….after all, if I am going to hide a body, I want it to be on MY terms. So, I decide (knowing this will not go over well) to ask Andy to swing by after his class to make sure that Jay is not pinned under the truck. Jay has decided that the only course of action at this juncture is to remove the steering box and see if we can press the pitman arm on. I was not there to see the dismantle – learning curve destroyed. Turns out he got the box off and was in one piece when Andy stopped by – I got chastised for being concerned…lesson learned: Give less of a crap. End Day 6 – Tuesday.
With the Steering box, all air tools, the socket and my sanity all loaded up in my vehicle - I took him to work with the expectation that we would swing by dad’s after work and have him take a look at it. After his inspection – it was determined that the darn thing was up the spline far enough to be effective and that we could begin the rest of the re-assembly. Heading home, a bit frustrated that we wasted so much time when we were already where we needed to be with the arm and excited at the prospect of being in the home stretch, headed west back across the river. We immediately started putting the box back on…but it wasn’t progressing. (Remember, I wasn’t there for the disassembly – so I am flying blind here.) He is barking orders and expectations. Nothing is working. Finally, I asked him if the box was bolted to the frame. Um, yes. And….was it when you removed it? Um, no. Riiiiiiight. We unbolted the box from the frame – slid it onto the intermediate shaft and tightened the collar bolt. Bolted the steering box back onto the frame (mind you I have installed and removed the 21mm bolts for this process no less than 50 times during this project….) Viola! Now to pray that the steering wheel is still set to center, since in his frustration to get the intermediate shaft in the box – he was turning the steering wheel (not generally recommended). We compressed and tightened the nut on the idler arm. I slid under the truck and reattached both the pitman arm and idler arm to the relay rod. We fought momentarily with the tie-rod ends. (Patience, young grass-hoppah!) And it was time to bleed the power steering pump and steering gear box (since removing it, introduces air into the system). Drum roll……..turn the key………nothing. A dead battery. Tried jumping it……nothing. A. Dead. Battery. Seriously? We are literally minutes away from total completion and we have a dead battery. This isn’t funny….not in the least. We pull the battery and plan for yet another delay. We pull the battery in hopes that Sears is still open. Nope. WOW. End Day 7 – Wednesday.
Before we move on…look at the line before this one. It says – Day 7. As in a week. A WEEK! And I still haven’t hidden a body…I am pretty darn proud of myself!
On my lunch break, I run the battery up to Sears with explicit instructions that after they charge it, they need to test it again and then call me to let me know it is good. It comes back solid. I pick up Jay – confident that we. are. almost. done! Yes! We get home, install the battery - mind you, the night before he dropped the tray bolt into the most inconvenient place on the whole truck, so 15 minutes was wasted recovering that. Go to turn it over to bleed the power steering system…..and the truck won’t start. As it would turn out, there was about an 1/8 of a tank of gas in it when he started this project and since the truck was up on jack stands and the fuel pump is in the front of the tank…yup – it was essentially out of gas. Yep….really. So, I get to go to the gas station and fill up a 5-gallon gas can so we can finally put this nightmare to rest. The gas worked and we started the truck. After another 10 minutes of bleeding out the steering system, and we were fortunate that the steering wheel ended up at dead center, it was time to put the wheels back on.
Jay put one on and I grabbed the other one. (Yes I can put a truck wheel back on the lugs…even when it’s on jack stands.) He took it to get gas and theoretically test drive it…in traffic. Not my recommendation, since I said go to the church and run some figure eights…. He said it was like new. I asked about the play in the steering – he said it was gone. Imagine that! And the dealership was trying to sell you parts you didn’t need…. End Day 8 – Thursday.
So we saved a ton of money. Lost a little bit of our minds. No one was physically maimed, mutilated or killed. I didn’t have to hurt my back digging a hole. Someone asked me if I had test driven it after the repair…. now why would I do that? Hadn’t I suffered enough? I didn’t need to die in a car wreck too! In all honesty, I knew we could do it….I just need to remember that two sets of eyes and hands are always going to be better if I can’t just do it myself. Still not sure if I would do it again though….and I can say that it was NOT a bonding experience in the least. 
Thanks for stopping by….