964 Case Through bolts

[VincentVega]

I'm looking for some advice installing the o-rings on the case through bolts.

The manual says to use tool P9511 to install the o-ring.



I tried a test run and cant see how the o-ring can be installed without the tool, or an equivalent.

In my search I found a thread suggesting a Sharpie can be modified to mimic the tool. Is this the common method? If not, is the P9511 the way to go? Where can I find this tool?

Thanks!

Chris

[TimT]

The cap from a sharpie looks quite similar to the P9511 doesn't it?

[john walker's workshop]

i went to the hobby store and got a piece of thin brass tubing that just fit over the stud. cut to about 2 inches and smoothed the ends. you still have to carefully poke the o-ring all the way in with a mini screwdriver. only use the green o-rings. never the blue.

[VincentVega]

Thank you!

[edbaus]

Heck, I have done this twice already and I just rolled them across the threads as best I can and let the washer push them on the rest of the way.

No issues. Maybe I got lucky.

Ed

[Walt Fricke]

I'm with Ed. Haven't had leaks.

The O ring gets mangled anyway when you tighten the acorn nut. In about a dozen engine teardowns (I don't keep count) I've found and saved maybe two or three of these O rings. You can keep the bolt from rotating by being careful always to hold it, but the washer on the nut side will.

But it makes sense to use a no buck option like the Sharpie cap, just in case.

I didn't know there was a color choice. Mine have been mostly blue - I bought a bag full at one point so I wouldn't be caught short at some point, as I don't buy gasket kits. They are my engines, and I can reuse whatever I want, and purchase separately when my stock of "good used" ones runs out for any particular one. These, and the oil pump/passage seals, are all that are inside the engine anyway. Well, the chain housing to case gaskets might qualify for being inside, despite being replacable without splitting the case or removing the cam carrier.

Walt Fricke

[VincentVega]

I thought this might help some one in the future.

I tried the sharpie cap route and wasnt happy with the results, I tested a few times with the blue o-rings and it was a bit comberomse. I went to the craft store and bought a few knitting needles, no dice, not quite right. After a little thinking I pulled out a few different old shell casings. It turns out a 8mm Mauser shell is a near perfect fit.

I cut off the primer end after I ran a drill down the inside to open it up a little. This little gem fit exactly over the through bolt threads and even has a little ramp to easily install the o-ring. I used a small, blunt, flat screw driver to push the o-ring off the 'tool' into the case, seems to have worked great.

[john walker's workshop]

same idea as the hobby shop brass tube. if you cut the tube with a tubing cutter, the cut end is rolled in somewhat. perfect for slipping the o-ring over to get it started.