Help navigating the tunnel of love

[chrismorse]

Hi guys,
Working on Dad's 74 coupe and need a big strong experienced guy to help me get from the front to the back- do not be jumping to any lurid ASSumptions here, this my first time- a plump 71 year old desperado looking to rehab, not a concourse restoration, on the car and I am dipping into the tunnel for the first time. Help me out here,

1. Do I need to disassemble the parking brake, throttle and heater controls to replace the fuel lines, are there any rentention, (bonding) clips there that need to get opened up to pull through new, "boxster" fuel lines, or anything else, "perishable".

Looking at the back end of the tunnel, gasp, I see, the shift rod, oh my, the speedo cable, evap hose, two brake fluid pipes, two p-brake cables, oh be still my beating heart, the main wiring harness, throttle cable, (rod), power cable to the starter, a pair of wires to the heater bypass valves on the heat exchanger, we got a lot of stuff going through the tunnel, and the fuel supply and return hoses, thankfully recreated by our good friend Len Cummings, of boxtergt,fame.

2. Am I missing anything besides the fuel lines that need replacing in the tunnel of love, on a vintage P car?

I am kind of serious about 1 and 2.

Thanks for my temporary side step from propriety,
Chris

[Drbraunsr]

I can speak with experience - the job is do-able yet miserable.
You will pull Len's lines from the rear to the front -- attaching your old line to Len's and pull it thru. Not much needs to be removed but is a b*tch . Patience is your friend.

If your engine and trans are out, bonus points for you.

I'll find a great thread with the picture of the tunnel sectioned wide open. You're going thru a tunnel in a tunnel.

[Drbraunsr]

Search: 1969 911e Tunnel Layout

[nomore]

I just did this to my 74 with steel lines, engine and trans in place. No fun at all. Whatever you do
don't let the old lines disconnect from the new ones. Use a small mirror and flash light to look
from the front to back and back to front. There is a short "tunnel" inside the tunnel near the shifter
the lines have to go through. A helper; puller/ pusher would be nice. The tunnel layout photos are invaluable. Whatever you do don't let the lines separate. Good luck.

[GH85Carrera]

Get the kit from Len. He has a coupler that makes attaching the new line to the old solid and secure. Get a helper. I tried for an couple of hours and ran from the front to the back wiggling and cussing. A friend arrived and with some coordinated wiggling and push pull, it was done in minutes. Getting the old grommets out can be difficult, and getting the new ones back in place will test your finger strength.

[chrismorse]

The mid year cars, at least the 74, do not have the threaded connection, so Len's suggestion was to run some stout string trimmer line through the old and new to do the pull.
Is it necessary or adviseabble, to pull the E brake/heat controll/hand throttle assembly, (like to get to a metal support clip), or is this asking for trouble and unnecessary?

Is it worthwhile to replace the speedo cable, While I Am In There?

Is it advisable to pull both lines at the same time?

What lube is advisable for the lines? Silicone grease, dish soap?

Any tricks to getting rubber plugs out or back in?

Since I will be doing the rear suspension/brakes next, I will support the transaxle and drop the front mount - any other suggestions?

Thanks,
Chris

[nomore]

Not necessary to pull the ebrake assembly as the fuel lines go through "the drivers side conduit".
Research Porsche tunnel layout.
I would start with pulling the bigger supply line first.
I pulled the grommets out with a screw driver, not really that hard; some people push them into the tunnel.
Since you are removing the trans mount and front mount this shouldn't be too awful with a helper.
I had my gas tank out for cleaning.
There are things the lines get hung up on so take your time, don't just try to yank the new lines through.

[chrismorse]

Thanks guys, great links & photos.
It looks like the channel on the drivers side protects the lines from the shifter and all the activity at the E brake area, leaving only one front and one rear set of "clips".
Any comments on the speedo cable, lube, or anything else as long as I am in there??

I too have the tank out, (as well as the pedal cluster) and will address the evap lines as well. Will also vac out 46 years of detritus before pulling the lines.

Thanks for the advice,
chris

[BoxsterGT]

Here is the Tunnel Layout that might be helpful to anyone contemplating this job.....



The Driver's side Conduit is where these Fuel Lines must go.

A common error when installing Racing Seat Belts is to unknowingly drill into the fuel lines, with disastrous results.

A helper is important. Flashlights and Quality Flare Wrenches are important as well. Don't forget the bent over metal tabs at each end of the Tunnel.

Grommets are the first to remove and the last to replace, allowing ability to move the lines back & forth doing the job.

Len

[bkreigsr]

"......Any comments on the speedo cable, lube, or anything else as long as I am in there??........"

My 76 had an annoying rattle/ticking in the tunnel.
After some research, I found that there are 3 plastic clips that are supposed to steady the throttle rod within the tunnel.
Long story short, I replaced the three clips - one in the coupler compartment, one behind the shifter tower, and one opposite the e-brake handle/heat control assembly.
I would guess that the clips in your 74 are in a similar state.
Here's the thread.:
83 SC Accelerator Rod

This would be a good 'while you're in there' project.

Bill K

[chrismorse]

Thanks bill and Len,
The three throttle rod bushings are on my list, as well as the evap hose.
I've got the new throttle rod, clutch cable, Len's late style hoses, Stomsky coupler, rubber bellows for the throttle rod and shift rod.
I will give the e brake cables a good look with the bore scope and look for any chaffing or problems with the wiring as well.

Is it worthwhile to do the speedo cable?

This ,"While I am in there", project has been going on for 6 years, (with numerous interruptions).

Speedo cable, or just pull and lube??

chris

[Damon in STL]

Originally Posted by BoxsterGT

.....Don't forget the bent over metal tabs at each end of the Tunnel.


Len

Where are these metal tabs and how are they best accessed? Are they the pieces just above the "er" in "Driver" in the pic?

[Solamar]

Originally Posted by Damon in STL

Where are these metal tabs and how are they best accessed? Are they the pieces just above the "er" in "Driver" in the pic?

Not sure what that lip is above the "er" but it sure gave me grief getting the gas lines passed it, kept getting hung up on it.

There are two metal tabs to deal with (at least on my '78).

The rear tab is just after the line exits the tunnel. It is also the mount for the rearward most throttle rod bushing (circled in red). The forward tab is near the shifter opening. It's a flexible piece of tin, just bend it up (or maybe it was down...). I think I have pictures of them, will look.

[Solamar]

Heres the rear clip, green X. You can just barely see the throttle bushing hiding behind the e-brake tube, orange plastic. Yellow arrow is the entrance to the tunnel looking forward.



another view of rear clip (green line). The throttle bushing is dislodged from it's spot, should be in the lower part of the clip -




Front clip (blue arrow) in shifter opening. Bent up in this picture -



And just for fun, a picture of the fuel lines entering the tunnel and that dumb lip that caused me so much grief (from front looking rearward). Also good view of mid throttle bushing -

[Solamar]

1978 SC looking from front to back -

[RWebb]

Solamar - is that pic for a '78 SC?

[Solamar]

Originally Posted by RWebb

Solamar - is that pic for a '78 SC?

Yes, updated the image with the year.

I'm not 100% certain I labeled the brake and fuel vapor lines correctly. They may cross at the rear. If any one knows, let me know 👍

[911tracker85]

great pics...

in final phase of grinding, sanding, cleaning tub for paint. I have a full set of fuel lines Len made me to install.

[911SauCy]

First you need to sweet talk it, and be ready with your patience. This isn't something that's going to go quick, and if you try, it won't let you.

You've got to find the holes, on both ends, plan your work and work your plan...

Just the tip at first...then send her home, but not too aggressively or else it will bind and you're getting nowhere...

Easy does it...

[chrismorse]

Great pics Solamar!!
Any tips on the cable replacement - the first time...you know what I mean🤑