Stiff Steering and popping noises

[Chef]

I just finished putting new ball joints on my 92 legacy, first time I've ever done this. Went well overall, a little bit of frustration trying to remove things, but all went in fine.

Problem now is thta my steering seems rather stiff and I hear popping noises from the front end (passenger mostly) when i turn left.

The ball joint on the passnger side seemed very stiff when I installed it. Is this possibly part of the problem?

The other thing is that I unhooked the sway bar when I changed the ball joint (top part of link). When I hooked it back up, i used my jack to lift it to line up the holes, and tightened it like that. Is it possible I tightened too much? Should I have tightened it without lifting on the control arm?

Thanks much for any replies.

BTW, I sprayed WD40 on the sterring u joints and then greased it up to help with stiffness (poorly though, quickie job).

I also have noted a problem while accelerating and steering. When I am accelerating aggressively, my steering seems ot stiffen a LOT, almost to the point of locking. This has been ongoing for a while, possibly getting worse. I have no idea why this is happening, my power steering fluid is up and looks fairly good.

Ideas?

[Threshld1]

check the torque on your pinch bolts, mine came loose slightly after i first put the new ones in (though i had to drill my pinch bolt out) and it was making some funky poping noises and stearing very erraticly and i brought it back to the shop, jacked it up and sure enough the ball joint wasnt seated fully into the knuckle. make sure they are flush when you torque it down.

yes ball joints are supposed to be quite stiff when they are new

[Chef]

They were definitely flush into the steering knuckle. I'll double check the pinch bolt tightness though. I didn't torque them too hard because the haynes manual suggested torque values of 15 to 20 lb/ft. I figured that wasn't too tight. Handling seems fine, better than before.

I suspect the popping MAY be the sway bar, but hard to tell. My other thought was that it might be the castle nut on the bottom of the control arm, allowing play on the bottom. But both were tightened to the point where they were well below the cotter pin entry, if anything possibly low enough the cotter pin was partially above the nut. However since there seemed to be no play in the handling or joints themselves, I think they're fine.

[Threshld1]

my manual said 35 (not enough for my through bolt let me tell you) on the pinch bolt *shrugs* double check your tierod end castle nuts too just for fun

i would check strut top nuts/springs. also is your steering rack/pump leaking?

[Chef]

The line that runs from my power steering pump just to the left of it has a tiny bit of sticky fluid on it, but the level is good and hasn't changed for since I've owned it (11 months). Maybe the pump is dying. I hear a loose bearing from up front (I think), and thought it might be the alternator. Maybe it was the pump.

I drive about 180 km/day to and from work, and the car seemed much better on the highway, the steering a little less tight and I don't recal hearing a pop since yesterday. I will keep an eye on it though.

While tie-rod ends seem fine, I checked the price for tie-rod ends (outer) - about $75 cdn each from Canadian Tire. Yikes! Life-time warranty ones. Well, my car is good for a life-time of another year or two tops. I will check the dealer but suspect an even higher price. Think I'll hold off for now.

[Threshld1]

yeah my pump is going, it makes fairly hatefilled noises and a constant highpitched whine and i just changed my front bearings so i know its not that (though it might be partialy due to my turbo also, not in the best shape). my alt is almost dead and i think its cause of the pump so ive got new ones on the way, ill post when i replace them

[Chef]

Well, I foudn the reason for the popping noises. The nut and bolt connecting the top of the endlink to the sway bar was hand-loose. Guess I didn't tighten quite enough. No problem, all taken care of.

My handing is much better than before, but still feels off. It may very well be the used struts and springs in front. The springs are from a 1990 legacy, and the struts from a 1999 impreza (or something around there). |The rear springs are from a 1990 legacy and the struts brand new. The guy I bought them from said the fronts still ahve some life in them (but rears close to shot), and they do, but maybe starting to reach the end of that life. Maybe just the springs. It just feels a little wobbly at times during quick back and forth steering, and responds to EVERY little bump - not harsh, just noticeable. Cross-winds on the highway still noticeable, but much less so.

For now it will ahve to do. I can't afford new struts and springs.