A (partial) list of the Chicken Wagon's repairs (unless otherwise
noted, replacement parts are used, not new):
Engine compartment:
- Pieced together and unclogged breather hose
- New O-ring in oil separator drain
- New O-ring on dipstick
- Adjusted and lubricated throttle linkages
- Cleaned fuse contacts, replaced blown tach fuse
-
Welded hood hinge latch together
-
Rigged broken hood hinge to sort-of pivot again
- Lubed hood pivots, latches, etc.
- Tightened coolant hose clamps
- 'Adjusted' EGR
- Adjusted ALDA, 1/2 turn CCW
- Picked rocks out of condenser
- Replaced missing fuse box cover
- New air cleaner mounts, added fourth (used) as bumper
- Fixed air conditioning
- Adjusted valves (chain stretch about 2.5°)
- Replaced burnt-out block heater (with new)
- Disconnected vacuum to transmission to reduce flaring
- Modified glow plug relay wiring to enable afterglow
- Fixed cruise control
- Replaced monovalve insert
- Replaced weeping fuel return line.
- Replaced leaking fuel lines (2).
- Replaced broken and spraying windshield washer check valve.
- Patched broken windshield washer fitting.
Body:
- Replaced turn-signal, license, and trunk bulbs
- Washed (scraped) off egg
- Cleaned out hood and door drains
- Polished paint
- 'Polished' black trim
- Rigged broken antenna mast and
romex to 'fix' totally missing antenna mast, later
replaced with a new mast
- Replaced broken cam in antenna (with new)
- Welded two door check straps back together
- Pieced together the other two door check straps
- Unjammed drivers door lock
- Patched broken passenger door lock toggle so that central
locking works
- Replaced interior front door release handles
- Cleaned out doors and lubed window sliders
- Cleaned out fuel sender
- Replaced rattling Kyb rear shock absorbers with good used Sachs
(from the SDL)
- Attached vacuum tank (rattled)
- RTV'd vacuum tank connection (leaked)
- Replaced rubber bumper for fuel door
- Glued rubber bits onto driver's door weather seal
- Glued rubber bits onto driver's door window seal
- Replaced left-rear door's weather seal
- Adjusted (bent!) driver's door window frame to cure wind leaks
- Cleaned and lubricated Sunroof
and its switch
- Welded on 'new' muffler
- New rear sway bar links
- Replaced right-hand turnsignal lens
- Replaced missing wood on left side of dash
- Replaced/repaired trim
- Replaced headlight doors
- Replaced broken taillight
- Replaced broken rear bumper (one side loose)
- Replaced leaking driver door vacuum switch (central locking)
- Replaced failed (welded) rear door check straps
- Replaced driver's-side air plenum grille
- Replaced wiper arms with ones that still have the nut caps
- Repaired (again) the passenger door check strap
- Replaced toggle springs in passenger door lock plunger
- Cleaned (and tested) neutral safety switch. (Was fine.)
- Reconditioned RF brake
- Reconditioned reverse lamp switch (cure intermittent shorts?)
- Replaced half-axles (due to split CV boots)
- Replaced ruined differential fill plug (and rear cover)
- Adjusted parking brake
- Replaced missing rubber exhaust donuts
- Replaced missing rubber clamp buffers for the hard fuel lines underneath
- New brake master cylinder, old was leaking (into booster)
- Rebuilt rear brakes. New seals, pads, and hoses.
- Cured minor surface rust beginning on bottom where undercoat failed,
especially where brake fluid had spilled.
- Tightened steering box screw 3/4 turn.
- Changed transmission fluid and filter, cured flare into 4.
- Replaced bad steering damper.
- Replaced (possibly-bad) idler arm bushings.
- CLA the RR (replacement) rear door check strap.
- Replaced broken driver's door handle, swapped lock cylinders to preserve keying.
- Hammer work to straighten driver's door where sign post hit it.
- Replaced driver's door trim.
- Re-welded muffler back on.
- Replaced transmission B2 piston.
Cabin:
- Washed all carpets and seats, including package shelf
- Screwed glove box latch together so the spring worked again
- Glued glove box wood back in place
- Replaced burnt-out dash lights, and re-connected light fibers
- Reconnected wiring to ashtray, new light bulb
- Resoldered connections in ACC pushbutton assembly (twice)
- Replaced fuse and volume control in Becker Europa
Cassette stereo
- Cleaned contacts in dome light. Repainted white stripe
- Disassembled and cleaned console window switches
- Disassembled and cleaned console hazard switch
- Replaced rotted ACC hose with pipe insulation
- Replaced broken eyeball vents
- Replaced driver's kick panel (from trunk)
- Fabricated new driver's seatback adjustment knob using broken SL knob
- Replaced sunvisors
- Replaced leaking oil pressure gauge
- Replaced missing clock
- Replaced dog-bitten interior panels
- Replaced dog-bitten steering wheel
- Replaced carpets
- Straightened passenger rear window lift mechanism
- Replaced missing driver's window exterior trim (wipe)
- Replaced front interior door release handles
- Replaced driver's seat with a good passenger seat
- Replaced shock cord in rear cargo pouches
- Replaced (and re-keyed) ignition lock
- Replaced ratty 'socks' around doors
- Replaced defrost actuator
- Repaired volume fader. Cleaned,
repainted the stripe and arrows on the wheel, and fabricated
(using epoxy, plastic bits, and black paint) a new end, where
some PO had torn a chunk out. Presumably trying to remove the
fader from the top with a screwdriver. I also took a speaker
decal from a junkyard fader. (It didn't fit in the hole, or I'd
have used it instead.)
- Combined two broken console window switches to get one good
driver's-side switch. Now all windows (and switches) work,
including the child safety lock switch.
- Replaced torn door windlacing with good used
- Replaced chewed driver's-side B pillar cover
- Replaced passenger seat cushion
- Repaired 'chunking' right-rear window regulator (again)
- Repaired slipping odometer
- Replaced damaged driver's seat belt.
- Replaced Becker with Alpine CD. Reversibly.
- Glued wooden trim back on with weatherstrip cement.
Still broken:
- Body dents, dead paint
- Windshield (have replacement, with new seal)
- Center dash vents (stuck on)
- Cracked and cut up dash (have replacement)
- Cracked wood
- Headliner hanging down in back (support wire loose)
- Small ATF leak.
- Center rear seat belt damaged.
- Driveline bearing support worn out. (Knocking under acceleration.)
- Monovalve insert torn
- Shift linkage bushings gone
- RR door check ruined
If I had a driving-age child this would really be an excellent
vehicle for him. It is my thought that a kid is hard on a car, and
tends to drive stupid too, and that if he had had to fix it up himself
in the first place he might be somewhat more careful. Also, Mercedes
diesels are great 'condom' cars: They're safe, slow, and his friends
(especially girl-) probably would not want to be caught dead in
one!
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