Hello!
This post (hopefully to become a thread) is a follow-up to the (very short) thread "1987 Corolla SR5 steering repair--need help from experienced mechanic" that I started after my recent (fortunately not-too-bad) collision with this car. The steering is now repaired, but the close inspection I did during that repair found a few new problems. Since (like Hachiroku) I love this car (a "hachiroku", i.e. an AE86), I am determined without a doubt to repair everything that is wrong with it, even if it costs several thousand dollars (US). (The logic for this is that I can't imagine finding another car I'd be as happy with for several thousand dollars). However, right now I'm looking at repairs (recent past and recent future) which I expect to come in at around $1,000 US total, including the steering repair of the previous thread. By the way, my car has only about 104,000 miles on it.
If all goes well, this will be the first in a series of threads that I will start about a series of repair projects that I have planned to do on this car this summer. About half of these stem from the recent accident and/or a hard pot hole strike the left front wheel took about a month or two earlier, mentioned in my previous thread. The others are projects through the winter I had been planning to do once the warmer weather came (and I had saved some money by working through the winter). Here is a list of all of them, prioritized:
- damaged suspension control arm --accident repair * starting with this post *
- front left wheel bearing noise --pot hole strike-related?
- body work (fender and bumper) --accident repair
- valve stem seals & tailpipe smoke @ warm-up --pending thru winter
And, if all goes well with the projects above, I will tackle:
- when cold until warmed up: runs rough, stalls, related issues
--pending thru winter
Some of these issues are further described (incidentally) in the explanation of the dynamics of the collision at the end of this post.
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Now, to address the control arm, the main subject of this post. When repairing the left steering tie rod, I did a detailed inspection of the front left suspension, comparing against the right side, and I discovered that the end of the control arm outboard of the strut bar (which triangulates the control arm) was bent rearward, with its rear edge bent upward. In the ball joint, the neck of the ball might also be slightly bent; I did not remove the boot to inspect it. I have learned that the control arm and ball joint are an indivisible factory unit, so that the ball joint will have to be replaced with the control arm anyway. The strut bar is OK and was not stretched; on both sides of the car, I measured the distance between the staked nut and the first hole in the strut bar and found it to be 14-5/8" (right on spec, within the accuracy of the measurement).
A local dealer parts department (Central City Toyota on Chestnut St. in Philadelphia) wants $212 US for the part. Because of the high price, I am considering buying a used part, either salvaged stock or U-pull-it. However, I am slightly concerned about the unknown of a used ball joint regarding durability and reliability. I need advice: Is it worth the $212 for a new control arm and ball joint vs. a used unit with unknown mileage wear and lubrication history? Can I expect a used ball joint to last the 100,000 more miles that I want the car to last? If a used part may be a good idea, should I only accept one I can inspect first (for example from a U-pull-it yard), and if so, how should I inspect it?
After writing the last paragraph, I have also found the part new at ToyotaPartSales.com (Dallas Toyota) at a discounted price of $150. (They list $212 as the MSRP.) They will ship within the continental US. Any caveats/words of caution? If I buy new, I'll probably go this way.
Also, are there any things to watch out for when replacing the control arm? I know it's recommended to bounce the suspension a few times before final torquing of all fasteners, and I'll do that. Anything else?
Finally, here are the physical dynamics of the collision, that I have deduced, which caused the damage to the left front suspension and steering: The collision flattened my left fender from its leading edge back to the wheel, exposing the front of the wheel. The exposed leading edge of the forward-pointed wheel then hit the other vehicle, and the wheel was wrenched outward, bending and cracking the internally threaded tube of the steering tie rod end (a.k.a. the outer tie rod). The rearward force against the tire was transmitted through the wheel, knuckle arm, and ball joint to the control arm, which was successfully braced by the strut bar, causing the end of the control outboard of the strut bar to bend backward. (This force also possibly bent it upward at the rear; the alternative is that the previous pot hole strike incident had already bent the end of the control arm upward at its rear.) The knuckle arm, wheel, wheel hub, and MacPherson strut assembly appear undamaged. Complicating matters, there was and is a preexisting condition of noise with rotation of that same (front left) wheel bearing, apparently indicating a wheel bearing problem; this may have been caused by the pot hole strike. Weeks before the collision, this noise was rarely and barely detectable but became progressively more noticeable over time; the problem remains (of course) after the accident but is not substantially worse than it was just before it.
About the apparently undamaged parts, I invite and request any suggestions about concealed damage which might have been done and that I should specifically inspect for. The same goes for any damage that may be invisible but that, in the spirit of conservative engineering, I should assume occurred.
Many thanks in advance to all who will contribute. Keep those Toyotas rolling!
Stephen