I'm getting ready for my 4th try at installing the upper steering column bearing with horn wire in my '49 GMC 1/2T. Every time I get the bearing seated as tight on the column as the old bearing was, the horn wire gets cut on the ridge that the bearing seats on. First time it broke, I bought a new bearing and horn wire. Not cheap, even from GM, which still carries them. Second time, with the second bearing and wire, I figured there must be something wrong with how GM built the new ones.
It looks like the old bearing had a deeper grove that the wire was soldered into. So I desoldered the bearing and smacked the groove deeper with a chisel on a dowel, then resoldered the horn wire into that.
Third try, same thing. I even dangled a vise grip from the loose end of the wire so I would know if and when the wire broke. The tool didn't drop, but I gave a little tug and the wire came out. Arrgh!
There must be some way to shield the horn wire so the bearing seat doesn't cut it. Any ideas?
