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  #1  
Old 05-26-2012, 09:31 AM
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Frame Rust at Thrust Rod Mounts - Advice / Parts Needed

My 1991 350SD was making clunking sounds when I turned the wheel, I looked underneath and juggled things around and didn't see anything. I took it to a shop and they found nothing. I had them check the alignment and it was OK.

Then it started making clunking sounds when I slowed down to stop and released the brakes. I got underneath and took off all of the under engine cover panels. The damage was hidden by the under engine covers.

I was horrified when with what I saw. I think it is the thust rod mounts on the drivers side (the bar goes underneath the engine and has a bar that goes forward to the control arm are broken in two places.

There is a lot of rust and when I inspected the other side it isn't yet broken, but there is some rust there too, and it should be repaired.

Some pictures are attached.

Obviously it is going to require some welding to fix it, but I need some advice here.

Have any of you run across this before? How did you fix it?

BTW: Other than this the car is in excellent condition. The engine has 30K miles on a rebuild with updated rods, new turbo, looks new, etc..

Attached Thumbnails
Frame Rust at Sway Bar - Advice Needed-driverssideimgp6885b.jpg   Frame Rust at Sway Bar - Advice Needed-driverssideimgp6886b.jpg   Frame Rust at Sway Bar - Advice Needed-passengersideimgp6891b.jpg  
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Last edited by Bob Albrecht; 05-26-2012 at 11:23 AM.
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  #2  
Old 05-26-2012, 09:54 AM
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Are you sure you are speaking of where the Swaybar Mounts?
The pictures show the Thrust Rod.

If there is no special repair panels made it would be nice if you were able to go to a Junk Yard and cut oversized sections of what you need so they could be welded in.

But, that brings up the issues of dimensions.

Body Shops have books that have points of measurement and dimensions so that can try to restore things back to normal. Without Having another Car to take measurements from I am not sure how that could be done.
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Last edited by Diesel911; 05-26-2012 at 10:29 AM.
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  #3  
Old 05-26-2012, 09:55 AM
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Wow. Horrified is what I would be as well. That is some serious damage in an important and hard to repair place. I would seek out a reputable shop with good insurance to get it repaired. If you cannot find a shop with good insurance and a good rep to do it,......keep looking.

Good luck.

Probably should not drive it until repaired.

I'd also have a good look at the upper sway bar mounts to look for damage there.

This is the sort of damage that puts older cars in the yard in many cases.
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  #4  
Old 05-26-2012, 10:10 AM
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Body shop, good idea.

There is a local body shop that may be able to do the job. I will check with them.

Has anyone else dealt with this? I want to gather as much information as I can, and since I haven't done any welding since high school I don't think I will be doing this myself.

I worry about cutting pieces out of another car because I don't know how strong those pieces will be.
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Biodiesel B100 when I can find it.
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  #5  
Old 05-26-2012, 10:13 AM
is thinning the herd
 
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edit: nvm read your last post.
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  #6  
Old 05-26-2012, 10:49 AM
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Quote:
Originally Posted by DieselPaul View Post
edit: nvm read your last post.
What do you mean?

Has anyone cut out those pieces to patch into a another car?
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Biodiesel B100 when I can find it.
Dino when really cold outside
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  #7  
Old 05-26-2012, 11:03 AM
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I had exactly the same problem on my 91 SDL. Drivers side gone, passengers side still there.

I had a new bracket made for the guide rod mount. The backing plate that attached to the "frame" (outlined in red) I had made to extend down the "frame" to well beyond the rust (that detail is not shown in the red outline). It was also made to rest against the corner where the "frame" meets the floor pan so the forces acting on the guide rod would be stopped there and the new bracket would not move when it use.

The piece of metal from the car that was still bolted to the top of the guide rod mount (best seen in the first photo) has a locating ring that holds the mount in place. This piece of metal was still good and was cleaned up and welded to the bottom of the new bracket (outlined in green).

I went to the machine shop with a cardboard mock-up of the bracket. The new bracket cost me $58. ( Actually, I traded a computer monitor for it. ) I think they used 3/16 steel.

I cut/chiseled what was left of the original mounting bracket off the "frame" rail.

The new bracket was bolted to the guide rod mount and guide rod mount and the cross piece to the other side's guide rod mount were reinstalled. Then with everything located where it was supposed to be, hard bolts were used to mount the new bracket to the "frame". The inside of the "frame" rail had no rust.

Then I got an alignment.

That was about 25k miles ago.

If you do not wish to go to all this expense and trouble, I will gladly give you $50 for your car as is.
Attached Thumbnails
Frame Rust at Sway Bar - Advice Needed-guide-rod-mount-bad-2.jpg   Frame Rust at Sway Bar - Advice Needed-guide-rod-mount-repair-3.jpg  
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2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

2007 ML320 CDI .. / 2005 E320 CDI .../ 1998 SLK 230 .../ 1991 Daihatsu Rocky
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  #8  
Old 05-26-2012, 11:08 AM
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If that area looks like that, have you inspected the rest of the car underneath?
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  #9  
Old 05-26-2012, 11:09 AM
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Here is why I want to save it.

Here is a picture of my car in the parking lot next to a much newer S-class.

It is actually a nice looking car.
Attached Thumbnails
Frame Rust at Sway Bar - Advice Needed-twomercedes.jpg  
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Biodiesel B100 when I can find it.
Dino when really cold outside
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  #10  
Old 05-26-2012, 11:14 AM
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Quote:
Originally Posted by pawoSD View Post
If that area looks like that, have you inspected the rest of the car underneath?
I have inspected the rest of the car underneath, and I did fix some surface rust. The problem with this area is that it was completely hidden under the under-engine cover.
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Biodiesel B100 when I can find it.
Dino when really cold outside
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  #11  
Old 05-26-2012, 11:19 AM
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Quote:
Originally Posted by GregMN View Post
I had exactly the same problem on my 91 SDL. Drivers side gone, passengers side still there.

I had a new bracket made for the guide rod mount...
Do you have a picture of it now?

Do you still have those cardboard cutouts?
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1991 350SD (updated rods)
Biodiesel B100 when I can find it.
Dino when really cold outside
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  #12  
Old 05-26-2012, 11:27 AM
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Quote:
Originally Posted by Bob Albrecht View Post
Do you have a picture of it now?

Do you still have those cardboard cutouts?
Come on, if I make it too easy you won't sell me your car.

Cardboard is gone. I don't have an "after" photo. The wheel hasn't been off since I made the repair.
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2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

2007 ML320 CDI .. / 2005 E320 CDI .../ 1998 SLK 230 .../ 1991 Daihatsu Rocky
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  #13  
Old 05-26-2012, 11:56 AM
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Maybe you can just turn the wheel and take a picture. My pictures were with the wheels on!
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1991 350SD (updated rods)
Biodiesel B100 when I can find it.
Dino when really cold outside
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  #14  
Old 05-30-2012, 02:53 PM
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Photo
Attached Thumbnails
Frame Rust at Sway Bar - Advice Needed-guide-rod-mount-frame-repair.jpg  
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Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

2007 ML320 CDI .. / 2005 E320 CDI .../ 1998 SLK 230 .../ 1991 Daihatsu Rocky
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