The "I can't believe this part broke" thread

[MSHardeman]

Mark,

The check arm swings freely in some open space behind, and above the jack storage area. I know this because I have Tone's door popper installed and I ran the wires for the solenoid up through that area and through the rubber boot to the back door. One day the popper stopped working and I finally found the problem was that the wire to the solenoid had gotten pinched and cut. The rear door check arm had pinched the wire against a metal "bulk head" back above the jack. Had to re-run the solenoid wire so it didn't go through that area again.

I have to say, that IS a very strange part to break.

[Ldub]

I broke the end of my ignition key off in the steering column...
This didn't completely surprise me, since I've been using my back door with a broken off key stub for a couple of years.

However, I couldn't get the ignition to work by employing the same method.

After trying for about a half hour, I finally bit the bullet & called a locksmith.
He messed with it for at least forty five minutes before calling in backup. The second guy diddled with it for another twenty minutes, & niether of them could get the broken off part out of the key hole.

Hmmmmmm...decision time, either have a flat bed come & haul Suzy to the nearest place that MIGHT be able to fix it (nearest Isuzu dealer, about 200 mi away)

OR, have the locksmith feller drill out the guts of the lock, so that I can use a screwdriver as a key...

You already know which choice I made right?

So anyway, the screwdriver technique quit working the other day...
Dink'd around with it for a couple of evenings after work, trying WD-40 etc...no bueno...
So last night I got a little more seriouser...
First i took the switch assembly off the back side of the lock...hmmmm, looks promising...
Put a screwdriver in & rotated one click, get accessories to come on, good!
Rotate it another click, get dash lights...OK.
Another quarter turn & the engine rolls over & fires up...SWEET!

UNFORTUNATELY...

When I try to put it in gear, the shifter won't move...stupid safety/anti theft stuff...

OK, fine, take the center console apart & jimmy the shifter lock until I can get it out of park & into some usable gears...

Better go for a little test drive. At this point I'm having visions of driving Suzy to work for the first time since last Friday...found a work around for every problem the dirty little girl threw at me...
Click her into drive, turn the wheel slightly to pull out of my parking space & CLICK...the steering wheel locks...@#$%^&*&^%$#@!#$%^ and a few other curse words that I don't know how to spell...

Back into my parking space, go into my abode, that's enough for tonight.

Called Merlin today, a hunnert-n-twenny something later, & I should have a new Ign module & a couple of keys by tomorrow, Fr @ the latest...
It was nice talkin' to him & according to his parts network computer, I got the last one in the country...SOMETHING had to go right eventually.

Tell y'all one thing, from now on, I'm having a new key made on my birthday, & destroying the old one every year...cheap insurance that...

[VX KAT]

I broke the end of my ignition key off in the steering column...
This didn't completely surprise me, since I've been using my back door with a broken off key stub for a couple of years.


Called Merlin today, a hunnert-n-twenny something later, & I should have a new Ign module & a couple of keys by tomorrow, Fr @ the latest...
It was nice talkin' to him & according to his parts network computer, I got the last one in the country...SOMETHING had to go right eventually.

Tell y'all one thing, from now on, I'm having a new key made on my birthday, & destroying the old one every year...cheap insurance that...

that's a frickin' nightmare Dub!

Would this help out?
OEM Vehicross lock cylinder with keys? $27.80.
Seller has "more than 10" ...anybody else want one?
http://cgi.ebay.com/ebaymotors/Ignit...6#ht_853wt_845

[Ldub]

So last night I got a little more seriouser...
First i took the switch assembly off the back side of the lock...hmmmm, looks promising...
Put a screwdriver in & rotated one click, get accessories to come on, good!
Rotate it another click, get dash lights...OK.
Another quarter turn & the engine rolls over & fires up...SWEET!

UNFORTUNATELY...

When I try to put it in gear, the shifter won't move...stupid safety/anti theft stuff...

OK, fine, take the center console apart & jimmy the shifter lock until I can get it out of park & into some usable gears...

Better go for a little test drive. At this point I'm having visions of driving Suzy to work for the first time since last Friday...found a work around for every problem the dirty little girl threw at me...
Click her into drive, turn the wheel slightly to pull out of my parking space & CLICK...the steering wheel locks...@#$%^&*&^%$#@!#$%^ and a few other curse words that I don't know how to spell...

Back into my parking space, go into my abode, that's enough for tonight.

Called Merlin today, a hunnert-n-twenny something later, & I should have a new Ign module & a couple of keys by tomorrow, Fr @ the latest...
It was nice talkin' to him & according to his parts network computer, I got the last one in the country...SOMETHING had to go right eventually.

Thought I'd update this, in case anyone is interested...

Today, I promised myself that there would be no black Fr shopping until I could drive Suzy to get there.
Spent the morning relaxing with Hunny Girl & downloading/printing pertinent sections from the VX shop manual in the downloads section, (THANK YOU VXinfo, that reminds me, a donation is in order...) then had a little lunch. (a known Nawthurn thing)
After it turned into a bright sunny day & the mercury nudged up above 10 deg, I decided to put on my woolies & go out to do battle with the beast.

As it was written in the manual of shop, & passed down to the Isuzuites...

Thou shalt remove all SRS fuses in the fuse panel on the drivers side end of the dash module. (drivers & passenger, covered by a yellow retainer, top right area of the fuse panel)

Upon the passing of at least 15 seconds, (I used the time to sweep the accumulation of about a foot of snow off the hood & windshield) remove the two star drive fasteners from the back side of the steering wheel, which will allow you to remove the padded center portion of the steering wheel. (which contains the air bag...duh)

Carefully pull the airbag assembly out far enough to access the wiring connections, then break the nearly 12 year old retaining tabs off of the wiring connector... I'm pretty sure temp played a part in this.
CAREFULLY disconnect the airbag connection.
Step back & give thanx to whatever Isuzu deity you choose to believe in, for not blowing your face off with an exploding airbag. (ignishnu is my current fave)
Disco the horn wire & carefully carry the airbag unit to the garage, store it in a place that will not be damaged, just in case...
Get back in the drivers seat & put reference marks on the steering wheel & steering column...more on this later.
After removing the retaining nut, realize that you should have bought a steering wheel puller. Press a small, two jaw puller into service...after whacking it with the breaker bar & having it slip off, go get a hammer, reconnect the puller, gripping the two opposing areas that haven't been marred by failure, tighten to what you think might be just below the breaking point of whatever Mexican alloy (seriously, there's a "made in Mexico" sticker on it) the center of the steering wheel is made of, give it a few whacks with the hammer &... BINGO!!!

Steering wheel off.

Started to remove the clockspring assy, then realized it would come off with the wiper/turn signal module, so went with that option.

OK, got all the peripheral crap outta the way, gots nothin' but the ign module & a nekkid steering column staring me in the face...

Thinking I had the worst of it behind me, I got this big dumb overconfident grin of my face...

Guess what?...can't get the ign module out...
There's a little button type thingy that clicks into a hole in the casting that won't move, & can't be depressed without the ing module turning...like with a key or screwdriver...hmmmmmmmm

(figured this out by examining how the new one works)

Having nothing to lose but my sanity, I got out my screwdriver, & asked Ignishnu for a little assistance...hey, it couldn't hurt.
Believe it or don't, the tumblers moved just enough for the little button thingy to retract & BAM, the ign module pulls straight out...SWEET!

Since it wasn't getting any warmer, I wasted no time in attempting to install the new ign module. OK, insert the new key, give it just enough turn to retract the little button thingy, (an industry term) & slide that sucker home...but - it - won't - go - in...

AaGGGGGGhhhh...@#$%(*&^%$#@#$&*(*&^%@%^&(/...!!!..

Using a flashlight & a mirror which fogged up every time I remembered to breathe, I examined everything I couldn't readily see from the drivers seat...nothing.
I then remembered that i had the switch module on the other side of the steering column removed, so I gave that a look & discovered that the transitional mechanism between the key module & the actual switch was rotated 90 deg from where it needed to be...once again, BINGO!!!

The rest went like buttah...

I got to drive my truck today...

In retrospect, this could'v been done without removing the steering wheel, if I knew then what I know now, & if I could have got the tumblers to move with a screwdriver.

And remember those reference marks? Due to the fact that there was "ample" oil on most everything inside the steering wheel, they totally disappeared. I figured out where the steering wheel should be by driving around with no retaining nut & repositioning the wheel on straight sections of road.

Hindsight = 20-20

Sorry for the "war & peace"

[VX KAT]

Amazing, simply amazing........all in 10 degree-ish weather!
It went down to 21 last night, and I was complainin' ??
And way more enjoyable to read than W&P !
Good to hear it all worked out for ya Dub and ya still have yer face too!

[uncle_asa]

I broke a lot of different things, but most unbelievable was front right upper arm:


I never thought that it is possible... And at least 600 miles on it in this condition (hopefully I did not knew that). I'm really lucky man

[Marlin]

I broke a lot of different things, but most unbelievable was front right upper arm:


I never thought that it is possible... And at least 600 miles on it in this condition (hopefully I did not knew that). I'm really lucky man

Wow, how did that happen?!!! That would suck. I have been fortunate so far, only the usual broken stuff Soon to add torsion bar bolts to that list. (see my SFIFS install thread)

[uncle_asa]

Wow, how did that happen?!!! That would suck. I have been fortunate so far, only the usual broken stuff Soon to add torsion bar bolts to that list. (see my SFIFS install thread)

I'm not sure when it happened. I suppose this was due to I lost upper bump stop and drove fast on unpaved roads. I suppose the another award in my rating goes to inner CV that I broke due to improperly adjusted lower bump stops after diff drop. So, double check bump stops are properly adjusted after diff drop, so CVs are still in allowed positions on maximum articulation.

[Ldub]

I broke a lot of different things, but most unbelievable was front right upper arm

WOW...that's a hit!

How much hang time ya get?