Front end rebuild, help me go shopping. What do i need?

[arcticathlon]

i posted this question in another thread, but was leading the original thread astray.

i am looking at doing a Front end rebuild on my 85 300D. everything except for the tierods (already changed) needs to be replaced. i would like to do as much myself as i can, but i am still a learning mechanic. i dont have any super special tools, and no air tools either. I HAVE replaced my rear axles, motor mounts, love doing valve adjustments, and smalller jobs. so i am not a total newb.

i know that the lower control arms will need to be done at a good shop or dealer, so in what order can i replace stuff then slowly drive it to the dealer to have them do the lower arms and align the car? also what parts do i order. if you guys can help me out that would be great. i would buy as much as i can from phil.

ohh ya, will get bilstein's comforts and new springs (from the group buy via this forum)

i will let the shop do the springs. i am lacking the expensive tools, as i am a recent college grad that lived in a small apartment. in march i will rent a house, and my job will allow me the liberty to stock my garage with tools. that will probably be the timeframe that i will be doing the rebuild.

another question, are ball joints hard to replace?

is there an easier way than just browsing phil's site for bushings/parts i would need?

[Wallknight]

Is there are reason you are doing everything all at once, or are you looking for advice on what to change first?

[Hit Man X]

Originally Posted by Wallknight

Is there are reason you are doing everything all at once, or are you looking for advice on what to change first?

Many of the jobs overlap.

[JimmyL]

might as well knock out everything when you have the spring compressor....

[arcticathlon]

ya that is the idea. i finally have a great job that will allow me to pretty much rebuild it. want to get as much done as i can in one swing. spring compressor i will leave to the shop also.

[Hit Man X]

Originally Posted by arcticathlon

ya that is the idea. i finally have a great job that will allow me to pretty much rebuild it. want to get as much done as i can in one swing. spring compressor i will leave to the shop also.

You can't do much without pulling the spring to be safe.

The tool is only about $200, cheaper than any shop bill could ever be.

[MarkM]

I have done the project you describe (complete front end rebuild) on my previous 300D, an '85.

the best way to look at this is that there are two basic categories of replacement components...those for which you need the spring compressor, and those that don't.

1) Need spring compressor

springs
ball joints (pressed into the lower control arm near wheel)..you need to
rent the special press to install.
lower control arm bushings (can be banged out with simple tools, and
pressed in with nuts, bolts and large washers.
guide rod mounts (attach at foot wells) (no special tools)
guide rod kit (metal rings and bushings that attach the other end of the
guide rod to the lower control arm near the ball joint (no special
tools)

2) Don't need spring compressor.

shock absorbers (remove tires for access, AND MAKE SURE THE LOWER
CONTROL ARM IS SUPPORTED WITH BLOCK OR BOTTLE JACK, otherwise
the whole hub will drop when you disconnect the shock and the main
spring will pop out and kill someone...the shock acts as the "stop")

steering shock (easy, no special tools)
tie rod assemblies (easy, no special tools, can be frustrating to separate
joints with pickle fork)
upper control arms (easy, no special tools, remove the tire for access,
and support the lower control arm with a bottle jack or block so the
assembly is not under tension)...in addition to the control arms, make
sure you get the rubber bushings...you need two for each upper
control arms, and they mount at the torsion bar.
drag link (easy, no special tools, can be frustrating to separate with
pickle fork)
idler arm repair kit....part of steering...connects pitman arm to drag link
(very easy, no special tools)




A few extra pointers:

DO NOT use any other type of spring compressor other than the one designed for this car. It is very straightforward to use, and very safe with this tool.

DO NOT disconnect shock absorbers unless the lower control arm is supported

All of these repair items are fairly easy and straightforward, however, you will need a couple of larger box end wrenches (19mm?), sockets, breaker bars, etc. for the bigger items (mainly the lower control arm bolts)

When reinstalling rubber parts (bushings, etc.) slather with silicone grease (Sylglide) to facilitate installation.

Get a set of pickle forks for separating the compression joints on tie rod ends, ball joints, etc. Also get a can of PB Blaster to soak joints. Also be prepared with a blow torch and a can of freon duster to heat and freeze a tough joint to help get it apart.

Use anti seize compound on all threaded joints, especially those that need to be adjusted during front end alignment.

When replacing bushings and ball joints in the lower control arm, remove the LCA from the car, mount in vise, do the bushings first (to minimize the chance of damaging rubber boot on new ball joint)

Removing ball joints is difficult...mount the lower control arm in big vise and bang like hell with hammer and chisel...be careful not to crack or chip or distort the lower control arm where ball joint mounts. Before installing the new ball joints, put them in the freezer over night, and press in when cold...makes it a little easier.

If you need brake pads, calipers, rotors, or wheel bearings, this is a good time to do these things, since all the stuff is removed.


I hope I haven't missed something. If I have, let me know and I will edit.

Good Luck,

Mark

[tangofox007]

Originally Posted by Hit Man X

You can't do much without pulling the spring to be safe.

The service manual does not support that notion.

[tangofox007]

Originally Posted by MarkM

I hope I haven't missed something. If I have, let me know and I will edit.

Is the lower ball joint mounted in the control arm or is it mounted in the steering knuckle?

[Hit Man X]

Originally Posted by tangofox007

The service manual does not support that notion.

Well I'd rather not have a spring go through my stomach.

[toomany MBZ]

Many parts available at ***************, also ***********************, have dealy with both, go with the lower price.

[winmutt]

I bought a front end rebuild kit off ebay for $290ish. Look around I'm sure its still there.

[rwthomas1]

You will need a ball joint press and a spring compressor. This job is fairly simple if you have these two tools and some time. Do it all in one shot. The upper control arms have balljoints and bushings already installed. Get new bushings for the swaybar, inners and outers. The lower control arms will need the bushings pressed in. I used a large C-clamp and various 1/2drive sockets to press the old bushings out and the new in. Do the lower balljoints and replace the idler arm, strut rod mount and the steering stabilizer. RT

[Ryan454]

you can rent the spring compressor from autozone for $40. and getting the ball joints pressed in can be done at any machine shop for around $50.

[tangofox007]

Originally Posted by Ryan454

you can rent the spring compressor from autozone for $40.

Don't even think about using an Autozone strut spring compressor on a Mercedes spring!!!!