Tuesday, May 26, 2015

Replace bearing and seal on front load washer

When the bearings start to howl on your front loader you have options.

1) Replace the wash machine.  This machine was (only?) ~10 years old.  It has worked great and the bearings were the only thing wrong with it.
2) Replace the tub.  The manufacturer sells the tub as a service item.  The cost is in the range of $500 including shipping.
3) Replace the seal and bearings.  The manufacturer won't sell you the parts but enterprising souls will for less than $100.  The project took several hours to complete but the education and sense of accomplishment have an intangible value.  When someone asks what you did last weekend you could actually have an answer.

Removing the tub from the washer chassis was straight forward and step by step.  It took the longest time.  Probably two hours.  I am sure the second one would be much faster.
 

This photo shows the condition of the seal.  You can see the water has started to cause rust on the 'wrong' side of the seal.


We used hot vinegar and plastic spatula to remove the soap residue that is left inside the tub.  There was not much consdiering the washer was in heavy use for 10 years.

I wanted to calculate how many miles were on the bearings after 10 years.  Let's assume the washer spins at 1000 rpm and each load includes 20mins of spin time.  For a family of six, we probably have two loads each day or would if we spread out the loads like that. 

1000 rev/min * 20 min * 2 loads/day * 365 day/yr * 10 yr = 146000000 revs

Further assume 0.3m rolling radius.
146000000 revs * 2 * pi * 0.3m = 275064000 m = 170916 mi


The bearings and seal are in the bottom of the tub.  You pound out the bearings just like you do (or used to do) on the knuckle of your car.  It takes some elbow grease but it's not difficult to do.


Re-assembly is simply a reverse of the removal.

Wednesday, November 12, 2014

2007 Dodge Mercedes Freightliner Sprinter Alternator Starter Y-Cable

I recently noticed the ScanGaugeII in my 2007 Sprinter was reporting a voltage below 12v.  I had replaced the main battery within the last three weeks.  So I connected my StarScan tool and confirmed the alternator output was 8.9v when I expected to see about 14v.  I had read that these trucks are famous for the "y-cable" that connects the alternator, starter and battery.  The cable runs transversely behind the oil pan and can easily be seen while looking from under the front of the truck.


The cable runs from the starter solenoid to the alternator.  In this picture it is not easy to spot anything unusual.
 This closer view shows the plastic convolute is not fully wrapping the cable.  It is deformed from heat.  The tape is also cracked from the heat.
 This is the same cable as it runs behind the oil pan.  In this picture, you can see the heat was enough to melt the convolute to the cable at the zip tie.  The bulge in the cable at the left of the image is the inline fuse.  The fuse is between the alternator and the starter solenoid lug.  The starter solenoid lug is at the middle of the cable and the second leg of the y-cable runs to the battery tray under the driver's feet.
I called Bob at Hoekstra Transportation.  They have the cable in stock and was quoted a price of $90.

This cable is reported to cause a great many engine codes.  That may be because the battery voltage gets so low since the alternator is trying to charge the battery through a corroded cable.

I will post more pictures and notes when I remove and disassemble the cable.

The removed cable:


 The end of the fuse close to the alternator got hot enough to deform the housing of the fuse.


It looks toasty.  Why was the alternator putting out so much current?


The new cable: A 906 440 16 41




 The cable did not fix any codes but I did notice that the battery voltage reported on OBD is more steady at 14.0 V +/-0.1 now.

Sunday, November 2, 2014

2007 Dodge Mercedes Freightliner Sprinter Steering Lock Module (Part number: 906 462 00 30)

2008 Winnebago View based on 2007 Dodge Sprinter


Symptoms:
  • I have an active code "9005 ECU Loss of communication and ECU timeout during unlocking".
  • No whirring noise when I insert the key
  • Most of the time no chime when I insert the key
  • Can't turn key.  Key would not turn.
  • The steering is unlocked but there are many failure reports of the steering being locked.
I made contact with someone from the sprinter-source.com with a Chrysler Starscan diagnostic tool.  He read the codes with the Starscan and determined that the 9005 code was still active.  We ran through the Chrysler diagnostics steps (check fuse and wire continuity) to determine the steering lock module is bad.


Schematic Ignition switch / Steering Lock Module
 The StarScan displayed 'Undefined' ELV Status.

The ELV is mounted underneath the steering column, near the driver's shins.
Part number: A 906 462 00 30

The ignition switch (EIS) communicates to the Steering Lock Module (ELV) using ISO-K.  The ELV contains a pin/bar that is driven up to the steering column to cause the steering lock.
ELV mounting location
 The security pin holding the ELV to the housing could not be removed (turned 180 deg clockwise).  It moved only about 90 deg because the lock pin/bar was partially applied.  I had to drill out two roll pins to remove the cover.
Torx security pin - turn 180 deg clockwise to unlock and remove
Hall effect sensor in the slot holding pin/bar
Magnet on pin/bar
 
Drive gear, lock bar/pin, cover, and housing.
Additional pictures:




Tuesday, April 7, 2009

The First Day of the Rest of My Life

The first day of the rest of my life started one evening while I was surfing Craigslist. I was not looking for anything particular, but I found it anyway: The job ad was rather spartan, but conservation of words intrigues me. Over the next week I made searches about the company on Google and then responded with a similarly terse email.

I heard nothing for about one month, then I was invited to phone interview for the position. The principal of the company and I talked for about 20 minutes while my kids were practicing sanchin-ryu. He told me what the company did and that they were looking at starting a new division that focused on my area of experience. The company is located out of my state, but he was considering expanding. Overall, it was a pleasant conversation.

Several weeks later, I received a phone call indicating that the principal was going to be in my area and asking for a meeting. We met and discussed the state of the industry, in general. He did not appear to be very knowledgeable about the industry, even to the extent of being surprised when I explained the processes we follow. He also asked about some items with which I am very familiar, but his questions were not of a technical nature. As I left this meeting, I could not tell if it went well or poorly. Finally, I decided that it went well because it was a long conversation.

After a few weeks passed, I received an offer letter in my email. The job appeared to be as we discussed and the salary was great, but the offer was in an other town and state. My wife and I discussed the offer and agreed that we did not want to relocate. I called him and explained that while the offer was generous, I would not be able to accept a relocation for more than a year. He said that a one year relocation did not make sense, and that we could open a local branch of the company. I was stunned, but at the same time, I was excited and flattered that he thought I was the right guy to do that. I agreed when he asked if he should have his people start drafting a contract.

We negotiated items on the contract for several weeks and I made more detailed checks into the company. I would be leaving a company that I liked and had worked at for many years, so I wanted to make sure of the decision. To that end, I asked a close CPA friend of my late father to review the financial statements of the corporation. He said they indicated there was plenty of revenue to pay me, the wage expenses were very low for the number of engineers I estimated he had working, and also that purchased services was somewhat high. My attorney reviewed the employment and non-compete/-disclosure agreements and indicated some areas that he wanted cleaned up to protect me and we made those changes.

I visited the headquarters of the company and met with the principal and the local staff. We had lunch and the principal paid, but his credit card was initially denied. The office was smaller than I had expected. We participated in a web conference with colleagues in another location and he also introduced me to one of the people who provided services for his company.

I signed the employment agreement and gave notice of resignation from my job. I completed my final two weeks and was excited to start the new chapter of my career. As I was leaving the former employer, I learned about the importance of asking questions about start up periods for retirement plans and health insurance. At my former employer, there was no waiting period for either. At the new employer, each had a substantial waiting period.

Day one: My first order of business was to find an office, which I did within a week. In addition to arranging telecom, furniture, etc, I was preparing marketing material for the new division. A substantial part of my responsibilities was to include developing new products, but the principal tended to ask more questions about past products than new ones.

My employment agreement provided for a car but, I did not receive one. When I brought it up to the principal, I was told that it was someone elses responsibility. Likewise, when I mentioned the need for a corporate computer, I was eventually directed to Craigslist, which again was not expected. Neither of these issues was resolved.

After two weeks on the new job, I received a note from a friend and former colleague saying that they had been advised to have no contact with me. After some sleepless nights, I learned the details: my new employer was unfriendly to my industry because of his testimony as an expert witness for plaintiffs in product liability cases. This caused me concern because part of my new job was to sell products and provide services to that industry. My most likely first contacts were being advised not to talk to me. I brought my conflict of interest concerns to the attention of my new boss, and he stated that it was his intention to keep the divisions separate. I felt this was dishonest and did not want any further part of it, so I resigned immediately.

Reality strikes:
While I was working, I felt like what I did had value and therefore, I had value. During the job search, I did not feel like I had value. I was depressed.

Mornings were bad because I no longer had a routine or responsibilities but, for some reason, evening time was the worst. After a couple weeks, I could feel my anxiety rising in the late afternoon. During the nights I would think, "I am intelligent. I am a hard-worker. And I would be employed if I hadn't made such an awful decision!" Many times I would lie awake in bed terrified about what was going to happen to my wife, my children, my home, my future. Fortunately for me, my wife was and is stable and steady. She said that she knew we could get through this because we are a family. That helped me more than she may ever know. She also pointed out that I could not change the decisions that had already been made - a powerful reminder not to dwell on things that I could not change.

Searching for a job in the current market (2009Q1) was a real eye-opener. Sending out resumes on jobs for which I am well qualified and receiving NOTHING or REJECTIONS is painful, to say the least. It was also emotionally painful when my oldest daughter asked me if I had a job. She asked this while I drove her to school one morning. After I answered her truthfully, she asked if I was looking for a job, what kind of job I was looking for, and if there were any jobs like that around here. Of course, all children are above average in the eyes of their parents, but that morning, the tears in my eyes, which started out being caused by my embarrassment about being unemployed, were from my pride in her problem solving skills.

A large portion of jobs are filled without being advertised, and it is likely that many of the jobs that are advertised are not actually available at all. Of course, I have no proof of the later, but the former is how I learned of the availability my current position. My former boss alerted me that a customer was looking for staff and offered a recommendation.

The time off allowed me to enjoy a lot more time with my family and I was able to make progress on some home improvement projects. Occupying my mind with projects was a good way to take a break from the situation. It also made me feel I had value.

Unfinished business:
I had spent many years progressing through the ranks at my company and I was satisfied with my career path, but while looking for a new job, I learned that I had not spent nearly enough time thinking about career development. I admire people who have a five-year (or longer) plan for their career, but I don't have one. I need to change that.