Need help with a suspension problem
 

I am removing the front Bilstien strut inserts on my SC to get them re valved. The left side roll pin came out with just a few blows of the hammer and punch. The right side is not coming out! Here is what I have done. First I used liquid wrench day after day, used the hammer and punch, and nothing. Next I tried tapping the end with a screw to try to "pull" it out, but the screw broke off in the pin. Next I tried drilling out the screw, and the bit broke of in the pin. Now I am left with a near solid roll pin. I got a carbon tip bit to try to drill it out again, but its not working (doesn't cut much at all).

What do I do now?

Take the whole strut off and have a shop get the pin out?

Sound as if the strut has to come out to get the pin out.
To remove the struct, you can also remove the large nut at the bottom of the A-Arm that secures the ball joint to the arm. I recommend purchasing the special socket tool to remove the nut and then use an impact wrench. Might want to consider purchasing a new ball joint.

Be sure to align the ball joint to the A-arm during installation (they are notched). I would also replace the other pin and use antisieze.

Good luck.

Here's a trick that's also useful when replacing pedal bushings. Use a vice as a press. You need a strong piece of pipe to back up the strut and something slightly smaller than the pin to use to push it through. Then crank the vice. I've found that a nice big bench-top vice work great.

if you have air, a skinny air hammer bit gets them moving. otherwise, use a long flat tipped drift, hold it with visegrips, and get a bigger hammer. they're a bit difficult because of the angle.

I am putting together a task list for a front suspension rebuild and this is a great thread. May I butt in with a few questions?

First, is that nut holding the ball joint as tough as they say to get loose? Any hints or tips?

Next, does anyone think that front torsion bars ever wear? If they do, is it recommended to simply pull the torsion bar and replace it, or am I better served by removing the control arm and replacing the bushes into which it goes? That is, do those bushes really get worn that hold the control arm to the body proper?

Finally, along with the torsion bar, new strut inserts, sway bar bushings, ball joint, and turbo tie rod upgrade, what else suspension-wise should I be taking care of at the same time?

Thanks very much!
John

Getting the nut off the Ball Joint can be a real PITA....
Maybe if the car is up on a lift it is easier because you are able to attack it easier. Some say a large hammer with a drift or chisel will lossen the nut but I had no luck. I goy my dremel and cut some slices in the nut an off it came. Got 2 new nuts and the tool to put them back on............