The Virtual Wall of Mechanical Mayhem

A collection of broken, mangled, and otherwise failed or failing parts that we’ve encountered in our shop.  Most of these vehicles managed to drive into the shop, this way.


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Cylinder head gaskets, 3.8L Ford Mustang. One of the stranger, and most severe head gasket failures we’ve seen.


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Ford van, belonging to one of our fleet customers.   Vehicle was losing coolant and overheating.  This is the upper surface of the head, where it mates with the intake manifold.  Not an ideal sealing surface.


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Extracting bolts from the Cam Sprockets on a DOHC Subaru EJ25.  Not a fun job, all 4 bolts stripped.  Two came out by welding on CV axle nuts, the other 2 came out with mechanical extractors (one internal, one external).   It takes a huge amount of torque to get these out.

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Corrosion inside a SU Carburetor from a Jaguar E-type.  We were able to save it.

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Behold, this pinnacle of welding expertise.  It was supposed to be a motor mount for a Cummins Diesel.   Of course, we didn’t do this, we were tasked with fixing this mess.

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This car drove actually drove into our shop on this lower ball joint.

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Common GM failure – now you know why they are called spider injectors

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Automatic flex plate.  They’re usually supposed to be in one piece.

 

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Probably the worst brake rotor we’ve encountered to date.

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This cam (on the left) actually came out of our shop truck.  It is missing an entire lobe.

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Volvo V70 XC transfer case.  Exploded when the rear diff locked up.

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Input shaft for the transmission on a Dodge Cummins.  Looked like a clutch failure at first.

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Volkswagen MK4 R32 Connecting rod.   Engine also came with a cracked crankshaft.

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Stripped flywheel, Ford expedition.   It is only stripped over a small arc – this is where the motor naturally likes to stop most often when it is turned off.

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Who knew that Rubbermaid built Monte Carlo fan shrouds?

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Completely imploded Subaru motor.

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Not much left of this water pump impeller.

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Bottom brake caliper bolt fell out.  Under braking, caliper pivoted out, and cut the rim like a pipe cutter.

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Tensioner pulley came loose, and sawed right through this timing cover.

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Brake pad missin in action.   Caliper arms were pressing directly on the rotor, and had worn about 1/3 away.

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Bummer.  Another picture from our shop truck.  Cracked bell housing from the ’74.

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About the worst internal corrosion we’ve ever seen.

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Spring mount on a Toyota Tacoma.   Housing rusted, and the spring mount collapsed into the tube, causing the axle lube to leak out.

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Rotor thickness is in withing spec – for a Mountain bike.  Not so much on this Ford Explorer.

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Customer suspected an exhaust leak.