When I had the problem, I went through all the same things...
I wondered if it could somehow be the linkage or something... since the threaded part coming from under the cowling seemed straight as it went through its range of motion, I figured that wasn't the problem. Besides, it was thight, and had never been damaged.
The passenger side worked fine, the driver's side was the troubled one.
I compared the old arm to a new one, and found all the angles identical.
The tensioning springs felt as strong as new, and the pivot point was loose and clean.
Gentle finger pressure on the arm caused the wiper to work just fine.
Bending the flat shaft of the arm seemed at first to help, but not for long.
In fact, almost anything I did seemed to work to some extent, but quickly stopped.
So I decided (strange as it seemed) that what was really wrong was that the angle at which the threaded stud comes out of the cowling was incorrect. Not off by much, but enough to matter. Combine that with the fact that the drive stud is about an inch long, and from there it's about 18 inches to the end of the arm itself (talk about leverage working against you), and I think you have a system that can fail due to very small variances. But I wasn't about to tear the whole thing apart just to see if I could change things around a bit. Besides, it was RAINING... I needed the wipers, not a design change!!!
What I did was loosen the nut that secures the arm, and put a semicircular brass shim under the lower area of the arm between it and the flange on the stud, thus slightly changing the angle of the arm with respect to the windshield after the nut was tightened.
I used .015 material. Still works, even at highway speed... :)
Brass shim stock in sheets or strips is available at just about any commercial hardware supplier... costs just a couple bucks, and cuts with a pair of scissors. I suppose that just about any material would do just as well... I happened to have a piece of brass shim stock around, so that's what I used.
You might want to try it before you start tearing things apart.
Good luck
Marty
'96 855T
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