Flimsy unprotected position sensors linkage!
Today I really got going with the front suspension clean-up. I even took out the 'position sensors' to give them a proper clean-up. I'm not happy.
Right front seems to have been tweaked at some point in its life (looks like it was pulled down, probably someone changing a ball joint and not disconnecting the thing - still works fine, just doesn't look healthy), but more than that,
it's the absolute garbage quality of the joining rod / ball studs.
I've popped them all out and cleaned out the sockets meticulously, then spun the ball studs (GM # 10271003) in a lathe (could be done with a drill in a vise), and buffed 'em all to a mirror shine.
If you haven't looked, it's a somewhat coated steel ball stud, and that gets pressed in to a plastic rod end. There's -NO- seal of any sort. So that means a grit of sand or salt & water and any other sort of shtuff can get in there and start chewing up the metal ball end and the plastic cup.
New (original) sensors are expensive imho - like USD180 (MSRP $305), though there seem to be some other brands selling for ~35 bucks. Not sure if I'd trust the cheap ones.
The little ball studs sell for about $6 a pop at their best...more often it's in the 12$+ range. I didn't bother looking up the rods with the plastic rod ends as no doubt they'd be priced insanely as well.
So the moral of today's tinkering might be, take a moment and have a look-see at all your position sensor bits and pieces next time you're in the area. If your car has never seen rain or dirty or dusty roads, you're probably okay, but for the rest of us...
I will consider seeing if there's something I could use to try to provide a bit of protection and seal off the ball ends so they don't chew themselves to bits.