Deceptively Difficult Repairs

[DirtyLittleSecret]

Wanted to start a thread pertaining to those repairs which seem like they'd be VERY simple, but somehow manage to be a real PITA.

Example: my wiper was acting all funny, and had only one speed (intermittantly mind you).  So, I decided to replace the motor in the rain.  Gust of wind comes by and closes the bloody hood on me just as I'm aligning the mounting bolts.  Also managed to drop the retaining nut down the fender...luckily it fell out the bottom.

Colourful words...best saved for special occasions.

So, what else have you found enjoyable?

[1976Scottsdale]

Water pump replacement for me.  I was unaware that there was a pump that did not have threads in the lower power steering mount hole.  What a PITA when I have everything else on and have ran the engine and then they refuse to take it back.  Threatened to throw it at the snot-nosed brat at the parts store last time.  His manager gave me the right one, silicone, antifreeze, everything, with an apology.

[78ScottsdaleK20]

I too replaced the complete wiper motor assembly in teh snow/rain/wind...in the driveway (BTW this adds to the degree of difficulty). When going to install the top retaining clamp to the wiper arm lever I dropped it and it slid between the cab and fender back by the firewall, (cold hands).

Not too difficult, but a royal PITA, but three clutches on a SM465, since owning the rig 4 years ago. First time was from a tranny rebuild, second time from a motor swap, and now a third time due to an oil leak on the brand new motor that soaked the clutch. Six valve cover gaskets, two Intake gaskets, one oil pan gasket and rear main seal, and finally...a new oil pan which cured the sap! Did I mention all done to Murphy's law...all repairs done only when its cold out!

Its all good when you can justify not having a car payment and you do the work yourself, that equates to new tools! 

[bigblock73]

Head gaskets on a 1990 Suburban...NEVER again! 

[nova801428]

The mechanical fuel pump on a lifted truck.....and I thought people always looked dorky sitting on the inner fender, I guessed wrong

[zieg85]

Changed the oil on the truck the first time since I got it.... 4 hours later after using a chisel on the little holes on the oil filter as it crumbled with the strap wrench.  K-Mart oil filters must be made cheaper than the rest with tin.  Sunday afternoon, right before the game.... Anyway got er done but never will I start any PM type service unless it is to check the oil.  Never did see the game.

[monte85]

replaced the electric fuel pump in the tank of my 87 v20. i dropped the tank during a cold new england november. after i was done, someone told me that you can unbolt the bed and slide it back to get to the sender.

[FlatBlack77]

Not a repair but still one heck of a frustraiting hour and a half.

My 77 came with a black rubber headlight knob that was well worn and very dirty and sticky. So I jumped on the oportunity for a shiny chrome one from a later model...well I pulled the old one out and put the new one in only to find that it wouldnt stay in. I ended up taking the whole knob assembly out and trying to get the knob to stay in and when I figured it out, and put the assembly back in, I couldnt get the trick down a second time. I did get it after awhile though.

very frustraighting on a hot day outside.

[okuma]

for me was replacing the door windows after i painted it..... if you have never done this- I dare you to try it! doing this alone in the cold and with out any previous experience on this  was a huge PITA. getting the rollers in the window rail was a lot of "fun"..... befor 1 of them broke. was very old and brittle.

 helpful tip always,always  install the big window first then the wing windows...  if not, it will happen like me, fumbled with them for at least 3 weeks . until pugsy here on the site placed how to install door window thread.. thanks pugsy!

[JJSZABO]

Front rotors on 2000 Ford Expedition - rusted solid to hub.    A job that should have taken me 1 hour turned in 12.  10lb splitting maul managed to brake the rotor enough to get penetrating oil into the rust.  Then broke the caliper slide pin getting the caliper back on.  Do not torque the pin to book specs - it will break (just snug in my opinion).  All this on a Sunday afternoon - a day before my wife has to use the thing for work. 

The addage "blood and grease do mix" is true.  My knuckles can prove it.  I finally bought a pair of gloves to wear.

[VileZambonie]

The slide pins are only 26 lb-ft of torque it's the saddle bolts that are hi torque values (169 lb-ft). My students make that mistake all the time! Trust me I make them torque every single nut & bolt.  Those front rotors are common for seizing to the hub. I usually cut the hat of the rotor with my torch and take the giant sledge to them to get them off so I know where you are coming from there!

[JJSZABO]

Trust me I make them torque every single nut & bolt. 

LOL   I learned that the hard way.

[loudnlow87]

HEATER CORE!!!