FWIW - I had a REMOTELY related issue years ago with one of my Corolla engines. The cap came loose while driving and the rod flapped around inside the engine as the crank shaft beat it up. Being financially broke and needing to get the car home I pulled the oil pan, found the abused loose rod hanging there and a loose and beat up cap laying in the bottom of the oil pan. Having very few options open to me and no professional guidance, I went ahead and got a new bearing, some plasti-guage that my friend’s dad told me to buy (I didn’t understand why at the time) and ultimately reattached the cap to the rod as best I could so I could try to get it home… on top of a hill, on top of a mountain.
Unfortunately the end of the rod was thicker now because it had gotten repeatedly slammed by the crankshaft so it did not slide as easily into its designated spot. I believe the cap was also warped on the inside since it was no longer had a perfect inner circle but has taken on a very slight oval characteristic.
As you can imagine, the engine did not like it and did not want to spin freely, but it was enough for it to BARELY run. It ran VERY sluggish and as I forced it to climb a mountain the temp gauge got hotter and hotter. As I finally pulled into the driveway, the radiator blew because the temp got so hot and the engine stopped. I rolled it to a spot off to the side and didn’t touch again for years. I assumed the engine was toast. Years later when I decide to use that Corolla as a parts car to fix other Corollas I decided to crank it just on a whim to see if I could drive it onto the rollback. Shockingly, it fired up and idled and purred like a kitten. I was baffled. My best guess was that the arduous journey home that night years ago had worn down the friction points to tolerances that the engine was OK with.
Anyway, I offer this story only as a brainstorming idea as to why this rod and cap is fighting you. Did something warp at the end of the rod or the cap, perhaps due to heat? Did anything get beat up? Perhaps you have the correct bearing but you no longer have a perfect circle within the inner portion of rod or cap and it is applying too much friction on the bearing?
I’m not saying for sure anything like that is the issue. The automotive minds l that have already commented have way more experience / knowledge then I do. However, I thought I would share the story in case it leads to a potentially useful idea at some point.
Best of luck figuring this out…
