[T3] Front Axle Troubles

[Chris J Valade <redyouth@juno.com>]

        I've gotten as far as I can for now in taking apart and examining
the front end, and here are all my questions and concerns so far:
        The stabilizer bar isn't flush with the left upper torsion arm,
should it be, or is a mm or 2 nothing to worry about?
        What purpose do the setscrews serve?
        How do I go about removing the speedo cable?
        I have been able to get both torsion bars and the stabilizer bar
out, but they are all attached to a torsion arm since I didn't have that
special VW pulley to remove them with when they were in the car, so I
need to know how I can go about removing them (and later installing them)
from the torsion arms without that special tool.
        The ball joint on the right upper torsion arm is bent out on one
side , noticeably but not horribly, should I replace it?  And the ball
joint on the right lower torsion arm sticks and feels like something is
in the way at one portion when I spin it in a circle around the edges,
what does this mean and should I replace this as well?  Also, all four
have some rust on them (on the portion that is exposed), but it doesn't
look like it would impact their performance, would it?  Also, does it
matter if a grease fitting is in the ball joints during regular to dusty
driving conditions, or should they only be put on to grease and then
removed?
        Any recommendations on how best to clean the ball joints,
including the ones on the tie rod ends?  All of these need replacement
dust covers, and the other right tie rod end had what could have been
dirt, but whatever it was it wasn't grease and it wasn't a (at least
working) lubrication of any sort.
        Now the whopper (in both price and labor): the front axle beam
has some holes in the wielding, one is quite noticeable and I was able to
fit a coffee straw through it, then a bunch of small openings which may
actually be sealed along the wielding.  In addition, and more
importantly, the right arm of the front axle beam that has the rubber
stops on it is bent so that it is impossible to remove the right upper
torsion arm without bending it in some fashion.  Is there any way of
remedying this, or do I need to replace the whole damned thing?  (Based
on the posts I could find in the VWType3.org archives, this seems to be
something that hasn't been previously addressed on the list, and
something that few have even seen).
        I already have a few sources for used parts, but I would also
like to know sources for brand new parts if I decide to buy them; so, any
suggestions?  For a refresher I need: retaining bolts for the right
torsion arm bar and the stabilizer bar, an upper and lower ball joint,
ball joint dust covers (including two for the tie rod ends), and a front
axle beam.  Of course, this is assuming I will need to replace all of
this.
        From what I can tell the steering knuckles, steering arms,
torsion arms, torsion bars, stabilizer bar, and tie rods are all fine,
although I'm suspect of the torsion bars since both sides of the front
end were dangerously low and I don't see how the problems I have
discovered so far could cause that--the right side, sure, but the left
side I'm still trying to figure out.
        I'm sure I'll only be able to finish this project because of the
list, so thanks in advance!  Also, I have a whole bunch of pictures of
everything if anyone is interested to see them for any reason--just ask.

Sincerely,
Christopher J. Valade

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