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Old 06-22-2019, 01:05 PM   #361
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Default Re: 99 SL2 rebuild thread

The '99 rear suspension is good again. After my debacle on the '98, I was really worried about replacing the drag links. With new links, greased and anti-seized bolts, we should be good for another 20 years. I was happy with the quality of the Dorman parts.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
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Old 07-08-2019, 10:49 PM   #362
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Default Re: 99 SL2 rebuild thread

Whoops - wrong car. Over to the '98 thread.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 08-30-2019, 07:55 PM   #363
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Default Re: 99 SL2 rebuild thread

Check out this rotor:


What causes this? Poor quality rotors? Plenty of meat on the pads but the inside of the passenger rotor is trash.


The 3 other surfaces of the rotors are fine.
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File Type: jpg IMG_20190830_175846635.jpg (89.6 KB, 116 views)
File Type: jpg IMG_20190830_175903158.jpg (105.4 KB, 166 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 08-30-2019, 08:33 PM   #364
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Default Re: 99 SL2 rebuild thread

Sticking/dragging pins usually and less than top shelf rotor material. The inside almost always looks worse that the outside even when everything is letter perfect.
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Old 08-30-2019, 09:42 PM   #365
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Default Re: 99 SL2 rebuild thread

Interesting. We got new pins, boots, and used sylglide at the rebuild.

Hovercraft duct Bondo work and brakes:


We went with the same Centric brakes I used on the '98.
Attached Images
File Type: jpg hovercraft bondo and 99 brakes.jpg (104.7 KB, 112 views)
File Type: jpg right rotor.jpg (91.9 KB, 112 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-01-2019, 04:36 PM   #366
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Default Re: 99 SL2 rebuild thread

The kid came home for Thanksgiving and the left front bearing sounds horrible. I think over winter break we are going to replace it. While we are in there, it is time for new control arms and a stock clutch. Which nut needs to be replaced? Is it the big nut that screws onto the driveshaft, like the one just threaded on in the picture below?


We did not replace those nuts. Would it be worth it to re-torque that nut?
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-01-2019, 06:37 PM   #367
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Default Re: 99 SL2 rebuild thread

We re-torqued the nut. They were tight. Looks like new bearings are needed.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-07-2019, 01:37 PM   #368
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Default Re: 99 SL2 rebuild thread

My new control arms, bearings, and nuts came in the mail.


SKF bearings made in Spain.
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File Type: jpg IMG_20191207_112012815.jpg (41.4 KB, 207 views)
File Type: jpg IMG_20191207_112053511.jpg (31.2 KB, 157 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-08-2019, 11:55 PM   #369
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Default Re: 99 SL2 rebuild thread

That is one job we have not had to do yet. I am sure my time will come.
Hope it goes well for you.
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Old 12-12-2019, 09:41 PM   #370
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Default Re: 99 SL2 rebuild thread

Thanks Mark!
My new, stock LUK clutch came in the mail today. I'll be glad to be rid of the stage 2 clutch.
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File Type: jpg IMG_20191212_175450547.jpg (55.1 KB, 75 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-21-2019, 01:33 PM   #371
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Default Re: 99 SL2 rebuild thread

The carnage has started. I'll have to get the livestream going.
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File Type: jpg IMG_20191221_103242317.jpg (96.7 KB, 73 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-21-2019, 09:03 PM   #372
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Default Re: 99 SL2 rebuild thread

Torn apart:


The snap ring was rusted in. Was a bear to get off.


We set it up in the EAA 1414 press.


The inner race came apart.


I modified a 3 arm puller to grab onto a small groove in the race. That didn't work. Then I dremeled a slot into the race, with the intention of splitting the bearing. It didn't split but it did spin and move out so I could pry it off. Sorry for the blurry picture.
Attached Images
File Type: jpg snack ring.jpg (97.8 KB, 70 views)
File Type: jpg torn apart.jpg (73.5 KB, 69 views)
File Type: jpg shop press.jpg (69.2 KB, 66 views)
File Type: jpg race and balls.jpg (90.1 KB, 69 views)
File Type: jpg IMG_20191221_175225256.jpg (72.3 KB, 137 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-21-2019, 11:34 PM   #373
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Default Re: 99 SL2 rebuild thread

I havent read the whole thread but what's wrong with the stage 2 clutch. Just wondering because I wanted to get one
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Old 12-22-2019, 12:33 AM   #374
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Default Re: 99 SL2 rebuild thread

Quote:
Originally Posted by chris's sc1 View Post
I havent read the whole thread but what's wrong with the stage 2 clutch. Just wondering because I wanted to get one
On initial startup, it was super grabby. When trying to do a normal engagement the whole motor would shake back and forth violently. Reverse was even worse. This was with all new factory mounts too. It took miles to wear in and the clutch engages way at the top of the travel. We have less than 20,000 miles on it and I am not sure how much longer it will last. The stage 2 clutch was the worst thing I've ever done.

Buy a stock clutch. Don't buy a stage 2.

Edit: here is the post.
http://www.saturnfans.com/forums/sho...&postcount=279

Did I mention the stage 2 clutch sucks?

Edit 2: this post in my thread by OldNuc gives links to other reference threads.
http://www.saturnfans.com/forums/sho...48&postcount=6

I read them all before I dove in. Was well worth the time.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018

Last edited by Waiex191; 12-22-2019 at 12:47 AM.
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Old 12-22-2019, 06:38 AM   #375
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Default Re: 99 SL2 rebuild thread

Quote:
Originally Posted by Waiex191 View Post

I modified a 3 arm puller to grab onto a small groove in the race. That didn't work. Then I dremeled a slot into the race, with the intention of splitting the bearing. It didn't split but it did spin and move out so I could pry it off. Sorry for the blurry picture.
You only bought the bearing, not the hub too? The whole kit isn't that expensive from Rockauto.
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Old 12-22-2019, 10:28 AM   #376
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Default Re: 99 SL2 rebuild thread

Quote:
Originally Posted by 454cid View Post
You only bought the bearing, not the hub too? The whole kit isn't that expensive from Rockauto.
Yep. In hindsight I probably would have bought the kit. Mainly because the new hubs look so nice.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-24-2019, 03:11 PM   #377
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Default Re: 99 SL2 rebuild thread

Here Adam is making a tool for pressing out the old bearings. We also turned down one end to use it for installing the hubs.


This is the tool for pressing in the new bearings.


Our initial attempt was to use PVC to support the knuckle. That didn't work! Found my 3.25" Milwaukee holesaw was the perfect diameter. Tried to turn off the teeth, then tried to pare them off. Failed. Used it with the teeth.


Here is the setup in the press. The bearing let go with a bang.


Two empty knuckles.


One screwup:. On the first one we did not replace the race that was stuck on the hub before pressing out the bearing. Don't do that!
Attached Images
File Type: jpg killing two bits.jpg (80.3 KB, 58 views)
File Type: jpg press setup.jpg (62.2 KB, 173 views)
File Type: jpg two empty knuckles.jpg (88.6 KB, 59 views)
File Type: jpg bearing install tool.jpg (67.2 KB, 57 views)
File Type: jpg toolmaker.jpg (75.4 KB, 126 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-24-2019, 05:05 PM   #378
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Default Re: 99 SL2 rebuild thread

Adam sandblasted the hubs so we can put them in an oven. We still need to get the busted ABS sensor plastic stud out of both of them.


Here is a scene from a couple days ago. Adam was pulling the car apart, Matthew was making a new hovercraft skirt with our new Singer sewing machine, and I was keeping them from killing each other.
https://youtu.be/vTVEcLWx8yk
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File Type: jpg IMG_20191224_134941827.jpg (57.3 KB, 55 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 12-24-2019, 09:06 PM   #379
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Default Re: 99 SL2 rebuild thread

Quote:
Originally Posted by Waiex191 View Post
Adam sandblasted the hubs so we can put them in an oven. We still need to get the busted ABS sensor plastic stud out of both of them.
Will you be freezing the bearings too? I saw a video the other day where a guy put his new bearing in the freezer over night....he did not heat the knuckle.

I would really like to blast my knuckles because they are so incredibly crusty looking.
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Old 12-24-2019, 09:08 PM   #380
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Default Re: 99 SL2 rebuild thread

We will freeze both the knuckles and bearings. After the knuckle and bearing assembly has stabilized I can see heating them up to 150 F together.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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