I've been trying to diagnose a strange clunk in the front suspension that's become noticeable after replacing the front shocks with Konis. In the course of pulling and replacing/adjusting things I have created another problem for myself.
I pulled the radius rod (the part which connects the LCA to the chassis under the bumper) to replace those bushings. On reassembly, the end that bolts to the LCA the two holes refuse to line up. No amount of pushing or pulling can make them, and I spent a good three hours trying various ways of getting the suspension bolted back together to no avail; tried putting the old bushings back on, no difference; something was always too far off to get that last bolt threaded. I would think the rod is bent, but if I flip it over the alignment of the holes doesn't change. I think there is just some trick to the reassembly that I'm not seeing... or the chassis is somehow mis-aligned... a shop replaced this arm last year (ball joint was worn out) and got it back together okay.
Those of you who have replaced a front LCA, have you encountered a similar problem bolting up the radius rod? In what sequence did you put everything back together? My car has been on jack stands for a week and a half because I was so frustrated and pissed off after banging on it for hours and accomplishing nothing, but I gotta figure out how to fix this since I want a car not a lawn ornament.