Turning a $5,500 Repair Into a $900 DIY Project
Introduction
At 6:30 AM on Saturday, Memorial Day Weekend, I was on my way to practice. Just as the Bluetooth connected and I was going to turn out of my cul-de-sac, the ball joint of my rusty 2005 Ford Explorer’s upper control arm broke, causing the wheel to sit on an angle, taking its driveability with it. It was a busy weekend and there was construction on the street prompting my dad to call a tow to a mechanic. Because the car has 4-wheel-drive, I had to wait for a special tow truck just to be quoted over $5,500 for a laundry list of issues plaguing my Explorer. That amount was significant, especially considering how much I originally paid for the car: $1,000. It seemed my Betsy’s time was up.
Sitting at a Standstill
While I took my time figuring out what to do, I knew that spending upwards of $5,000 on a car I already own was not on the table. I decided to have it towed back to the driveway while I left for the Naval Academy Summer Seminar, awaiting its fate. I couldn’t afford to not keep my car. I had to fix it myself.
Where Do I Begin?
The first step was research. I spent hours looking at open repair manuals, YouTube videos, and part specifications to find everything I needed—all of which was on RockAuto. My total for the parts came in at just a fraction of the original quote. However, I still didn’t have everything I needed. I didn’t have a garage full of tools, but I knew people who were able to fill in the gaps. By being resourceful and calling on family members and friends, I managed to borrow every specialty tool I needed to get the job done. The trickiest to find was a torque wrench that could verifiably reach a torque specification of over 250 ft/lbs.
Rain or Shine (Lots of it)
Over the next few weeks, sometimes with a combination of an umbrella and a fan, I methodically worked through the extensive list from the mechanic. The full job included replacing the:
- Rear wheel bearing hub and knuckle assemblies
- Front upper and lower control arms
- Front CV axles
- Front drive axle seals
- Front Differential main and pinion seals
- Tie rod ends
- Front wheel bearings and hubs
A Lesson in Creativity
For multiple weeks, I had a semi-permanent layer of grease and motor oil on my hands and on a few throwaway white T-shirts. There were many times under the car that I had to just take a step back, get an ice cold Snickers, and take a look from a different angle. With each stubborn bolt, and even more stubborn solution, (including frequent use of a sledgehammer) my confidence grew. I was, piece by piece, bringing my Explorer back to life.
Some Tools and Parts
New Stuff
Conclusion
In the end, the total part cart was about $900, including some extra bits like socket sets and pry bars. By doing the work myself, I saved over $4,600. Along the way, I learned a lot and turned a disaster into a rewarding challenge.
