Getting through inspection: Golf check engine light, headlights, wheel bearing...

No pics from this round, as I did it in a bit of a hurry.  Golf failed inspection on three counts- bad rear wheel bearing (I knew it needed to be done but thought it would last a bit longer), headlight lenses were too clouded over (never heard of failing inspection for this!), and finally, the check engine light kept coming back on, no matter how many times I reset the fault code.  It was throwing a 'intermittent open circuit' for glow plug circuit number 3.

I installed a new wiring harness for the glow plugs, and 4 new plugs- that took care of the fault.  A headlight polishing kit from Autozone took care of the headlights, and I did the drivers-side rear wheel bearing.  Given my other experiences with wheel bearings on these cars, this one went surprisingly well!

Getting through inspection: Trooper- Steering box

State inspection time is always nice- it gives me a chance to see the cars up on the lift (since usually there's something the inspector wants me to see)…  This year the trooper finally failed for the leak in the power steering box.  That leak had been there since I bought the car in 2003- in fact the previous owner had a rebuild kit with gaskets that he'd given me when I got the car…  But I hadn't done it since it didn't really leak that much and had never caused me trouble…

Turns out I got to learn about recirculating ball steering!  Google it if you're interested- it's a fascinating design.  

The pump on the bench, ready to be rebuilt.  Just getting to this stage required several special pullers to remove ball joints etc...

The Ball Screw- this moves ball bearings that in turn push the piston that moves the Pitman arm (which then moves the wheels back and forth):

This is the interior of the piston that drives the pitman arm… 

It was pretty cool to see the interior of this thing- but it was a bit of a pain to rebuild…  In particular I was surprised by the ball bearings when they fell out of the box all over the garage floor- fortunately I was able to find all of them…  Always learning!

Exhaust(ing) work, take 2- Golf

I'd noticed the Golf sounding louder for a little while, but I'd been able to ignore it…  Until the thing finally actually fell off (and unfortunately stranded Suzanne):

 The break was right at the back of the Catalytic converter.  Midas (and really anyone online) wanted $800-1000 for a replacement pipe (unlike on the Trooper the rear pipe was fine and I just needed the front section, which was available, just really expensive!)…  That didn't seem right.  So I pulled out my grinder, torch, and went and bought a $8.39 pipe section from Advance Auto Parts…

A reasonably nice weld, even if it's ground down smooth...

I realized my repair section was actually a bit bigger than the original pipe I'd had, so it didn't fit in the existing joint with the rear pipe- so I had to harvest a short piece of the original pipe (which was in ok shape) and weld that on the back end to make it fit:

 The finished pipe, ready to install.

 To prevent this kind of thing from happening again (I noticed that the pipe had failed where it had been welded- makes sense sense the aluminized coating would have been burned or ground off in the welding process)- I painted the welds and actually the whole catalytic converter with POR-15.  Hopefully it lasts a good long time!