Nissan Repair: 95 240sx control arm breaking and problems starting, nissan 240sx, radius rod

Question
Dear Mr. Sudderth,  I have a 95 Nissan 240sx.  I've had it for about 3 years.  The front control arms keep breaking where the radius rod bolts to it.  I have no Idea why.  Its like the metal is flexing back and forth until it weakens enough to just snap off.  After that if I apply the breaks the car pulls hard to the left.  I'm not driving it because I know its dangerous.  This is the second time in less than 2 years.  Its not too hard to change but at $160.00 each its becoming kind of annoying and costly.  Why would it be doing this and what can I do to stop it from happening?  My second issue is that my car is strange about starting.  It is like the battery is completely dead, but its not, I know for a fact from testing it.  When I turn the key it makes one click like the starter engages but doesn't do anything.  I have to turn the key rapidly for it to start(about 15 times in 5 seconds and then it starts right up).  But sometimes I get in and turn the key once and it turns over the first time and it starts.  I thought it was the solenoid so I put a brand new starter on it.  It worked normally for the 1st day  after I put the new starter on it but then back to the same old thing.  It has an old "carbide" alarm that is disengaged.  what could this be.  The alternator is fine and the battery is fine.  Thanks for your help.  The front control arms are my biggest problem.  Thanks again.  Austin  

Answer
Austin,

Change control arm and make sure that the radius rod is bolted on tight.  Also, do not tighten the lower control arm until you have established ride height.  That is, donot tighten up the bolts that the arm pivots on until you get the car on its tires and then bounce the car a couple of times.  Then, get under the car without jacking and tighten the bolts.  Pre-stressed bolting of the bushings will cause a control arm to crack over time as well as make the car handle strange.  I would suggest you remove the starter and take it to Checker or Autozone to get it checked.  From what you describe I think you have a starter that has gone bad.  I think, if you are getting a click at the starter the replacement you have is defective.