Special Tools

[randywebb]

There are a lot of threads on specific tools, on what comes in the cars' tool kits, on what brand of hand tools are 'best', and so forth, but I have not seen a thread on what uncommon tools one needs to have to service the car.

For example, even such a s simple task as the removal of a rear brake caliper can require a special tool (guess how I know). Of course, it shouldn't but that is another matter.

So I thought I'd start a thread for uncommon tools that one needs. Let's keep the common tools out of this thread and on the "Essential Tools" thread:
Essential 911 tools


To remove a rear brake caliper you may need to make a tool like one of these:
http://forums.pelicanparts.com/porsche-911-technical-forum/344766-rear-caliper-bolt-access-post3255530.html#post3255530

There is also a wide range of tools for spreading the brake pads (a C clamp is fine if the caliper is dismounted); otherwise:
What is the best tool for separating brake discs?
Brake caliper spreader - Porsche special tool
Pelican Tool to Spread Brake Pistons?
[I missed the 1st two threads when I searched (!) - the last thread also gives a couple of other tools & tips.]

Banding pliers for CV joint boot clamps (I use zip ties to be honest):
CV Banding Tool how does it work

[randywebb]

A jar of Coleman's Mustard can come in handy as well:
Caliper dust boots - need help

[randywebb]

More on the caliper dust boots:
Need help installing brake caliper piston dust boots...Grrr!!!

[randywebb]

If you ever have to mess with the 14 pin engine to chassis electrics connectors, then a test wire can be handy. For that you need to find one of the special pins (maybe at a junkyard).

[rnln]

How about the super thin wrench to adjust rear heigh (adjustable spring plate on 87-89 botls). Anyone home-made it?

[defcon65]

Originally posted by rnln
How about the super thin wrench to adjust rear heigh (adjustable spring plate on 87-89 botls). Anyone home-made it?

I looked into getting thin bike wrenches in 24, 36mm sizes to do the job but they were anemic looking and $15 each, no bargain. The tool Pelican sells is much heftier by comparison, designed to do the job and $30.

[randywebb]

Anybody recall the URLs for those threads on making your own Z-block?

[kimlangley7]

36mm wrench for oil thermostat

[rusnak]

awesome idea for a thread! I'll look into my unusual but ESSENTIAL tool collection.

Front Spindle Dust Cap Removal (removenderdustkappen):

[Porsche_monkey]

Somewhere I have a clamp with pusher screws for removing rusted torsion bars (rear).

And a spigot with drill bushing for drilling out broken exhaust studs.

[2.7RACER]

Here is how I modified my compression gauge for easier starting into 911 motors.

[2.7RACER]

Here is my method of pressurizing my combustion chamber looking for leaks. AKA, poor mans leakdown tester.
1/4 pipe screwed into a modified sparkplug.
Made from junk laying around my shop.



Close up of modified sparkplug.



Be careful. 100 psi will rotate the engine quickly. Better to use 30/40 psi.

[2.7RACER]

This is my slightly modified 17/19mm box wrench for reaching the lower inside 930 rear caliper bolt on my '76 911. The bend clears the 17mm end from the inside of the body.

[rusnak]

I have one of these (14mm) to remove/ install the CHT sensor. It is the best way to properly torque the sensor to spec.

http://www.thetoolnetwork.com/sensor_socket__1.html



This tool is not unusual, but it is vital if you want to remove a front strut. You have to disconnect the tie rod without tearing the rubber boot. If you look at your tierod end, the pin has a globe shaped depression in it. The little ball bearing on this tool fits right into the pin and presses it right out. It does not make contact with the rubber, and it works every time without tearing the rubber boot.



spark plug pliers


ride height wrench

[defcon65]

I don't have any pictures to share, but I've found my vernier caliper, telescoping magnet tool, fingertip 'speed' ratchets and collection of small right-angle screwdrivers to be invaluable in many applications.

A cheap digital camera is great to snap pics of assemblies for later reference when you need to put them back together. I lay them out on a shop towel in 'exploded parts diagram' fashion then box or bag them up to keep the parts seperate.

I recently discovered that the $3.99 investment I made in a set of T-handled hex wrenches from HF may be the best tool investment I've ever made - I have used the heck out of them and they are vastly superior to the dozens of loose, small hex wrenches I've collected over the years. Surprisingly durable, too, and color-coded to boot.

[scottb]

Originally posted by rusnak
I have one of these (14mm) to remove/ install the CHT sensor. It is the best way to properly torque the sensor to spec.

http://www.thetoolnetwork.com/sensor_socket__1.html

Kinda spendy at $30 plus shipping. I made my own with a $5.00 socket from AutoZone and about 15 minutes with my Dremel and bench grinder.

[rusnak]

hey Scott,

my hat's off to ya! I agree, why spend money that you can save?

My problem I guess is that I get really cautious about some things. I debated back and forth with myself on that sensor socket until I finally decided to get the pro quality socket to avoid damaging the aluminum head. I'm also lazy, so it was easier to just order it online than make one in the shop.

[randywebb]

Rear Wheel Bearing removal tool - top post by Wavey

http://forums.pelicanparts.com/porsche-911-technical-forum/179300-rear-wheel-bearing-removal-post3264947.html#post3264947

[rusnak]

Here's an interesting tool.

If you need to remove the side mirrors on a '74-'89 911 then you'll need this tool to separate the wire harness from the individual wires. If you don't have this tool, then you'll need to either cut the wires or try to release them from inside the front trunk, and thread them out through the mirror housing.

I got it from Baum Tools.




Here's a closeup of the slotted socket. I hope to help anyone else who wants to make one at home. You need to start with a deep socket. I think a pneumatic right angle die grinder would be the best tool to cut the slot.

[Porsche_monkey]

These are very useful for broken wires/tracing:

http://www.mcminone.com/product.asp?catalog_name=MCMProducts&category_name=3830517&product_id=74-335