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Costa P 10-17-2018 01:26 PM

DIY tool for external oil thermostat cap
I eventually succeeded to remove the small cap (oil pressure relief).

This was my 3rd attempt after 2 previously failed attempts....more about those here:

I figured it may help someone else to know what worked for me, so here goes:

The mild steel “coin” was from the failed attempts. It twisted without handling much torque. I hacked the high strength steel version out of a chisel! It went into the slot nice and snug with the aid of a hammer.

The high strength steel version got the job done like a breeze. I used a 600mm long power bar with a 21mm socket over the hex of the chisel.
Surprisingly, the tip did twist and deform!

Costa P 10-17-2018 01:37 PM

Removal of large cap (thermostat)

I used a friction spanner to loosen the 50mm cap

75 911s 10-17-2018 01:43 PM

Nice! love the custom tool. There's a pretty cool replacement cap that a member makes that has a hex pattern built into it, not that you need it now. :-) I think on mine I soaked overnight with pblaster and then used cut a piece of thick aluminum as a key. Mine was obviously not as "on there" as yours though.

2jmotorsports 10-17-2018 02:40 PM

What a timely DIY. Im about to do this myself.

Also, for your hardlines, I was able to remove mine with no drama soaking with PB Blaster once a day for a few days then hitting each fitting with a propane torch. After about 2-3 heat cycles and the use of these wrenches:

All 4 hardlines came off with no issue.

JimmyT 10-19-2018 07:57 AM

I made these up to simplify the remote thermostat plug removal process.

I also make plugs with hex heads for easier removal.
FS: Remote Oil Thermostat Press Relief Cap, 916.107.276.00 (Small), $21.38

FS: 911 Remote Oil Cooler Thermostat Cap, 911.107.155.00 (Large), $25.62

Costa P 10-19-2018 11:02 AM
JummyT, those tools look awesome and the hex caps look even more impressive 👍🏻👍🏻

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