Flapper box cable connection and cotter pin
 

All,

When pulling my flapper boxes to clean them up, the bolt that holds the cable to the flapper box vane snapped. Fortunately that was all that snapped. All the nuts came off smoothly, disassembly and powdercoating went swimmingly, and reassembly of the

Unfortunately, I don't know the pieces or arrangement that attach the cable to the vane, since that was entirely oxidized. Can you help?

The PET shows the bolt (16) coming up from the bottom, then a washer, the vane, a lock washer (presumably, it's called "lock ring B4") and a nut.

Does the bolt really come up from the bottom?

Between which two pieces does the cable go?

The PET shows, and I have in my ziploc bag, a cotter pin (14). Where does that go?

http://forums.pelicanparts.com/uploa...1398368446.jpg

Here's someone else's flapper, worse than mine, which makes it appear the nut is on the bottom rather than the bolt (from http://forums.pelicanparts.com/porsche-911-technical-forum/451794-heater-flapper-box-valve-73-911-a.html)

http://forums.pelicanparts.com/uploa...1232224285.jpg

Same with this one (from http://forums.pelicanparts.com/porsche-911-technical-forum/397037-heater-flapper-box.html)

http://forums.pelicanparts.com/uploa...1204927369.jpg

Oh- and has anyone seen number 20 (connecting piece)? I haven't.

The cotter pin goes into the 'base' of the flapper to attach/hold one end of the spring.

^^^^ correct on the cotter pin and yes the bolt comes up with the nut tightening down the cable

Thanks- I remember now. NO wonder the spring was such a pig to get into the hole.

Which means the cable runs on top of the vane?

No......cable runs below the vane as in your last picture.
The bolt has a hole in it that the cable passes through. A washer on each side of the cable and the nut.

Pete,

The hole is probably 4-5mm from the head. If it goes bolt, cable, washer, vane, lockwasher, nut there's a lot of bolt (with a shoulder sized exactly for the hole in the vane) hanging down.

The threaded part of the bolt has a smaller diameter than the shoulder and the hole in the vane. If the threaded part of the bolt passes through the vane, it seems like there would be lots of relative motion (i.e. slop, leading to loosening) between the cable and the vane).

What am I misunderstanding?

Dru

I think the nut snugs against the wire and leaves the upper part of the bolt to rotate in the vane. Ken

So here's what the bolt looks like.
http://forums.pelicanparts.com/uploa...1398495557.jpg

The shoulder is an obvious fit for the hole in the vane. Could it really be that it's not supposed to fit there?
http://forums.pelicanparts.com/uploa...1398495581.jpg

However, the way I fitted it up (from the bottom bolt, washer, vane, wire, washer, nut) was too tight. I'll try it again today with a better idea. Got one?
http://forums.pelicanparts.com/uploa...1398495603.jpg

Note that properly installed cotter pin in the background!

I'd have to say the parts diagram is wrong. Strange. Mine and one I worked on yesterday is like your second pic.

First off, I have only looked at a flapper after it had been removed from the car, you get what you pay for.

I think that RDM's second pic with the bolt shows the correct orientation for the bolt. What is missing is the two washers. The control cable goes between these two washers.

Hopefully two pics of mine will show up below. I have not looked, does our host sell these bolts and washers?

Thanks


http://forums.pelicanparts.com/uploa...1398893249.jpg

http://forums.pelicanparts.com/uploa...1398893345.jpg

I had my original washers so I didn't check on their availability, but the bolts were available.

They were identified as Clamping Screw M4x11, 911 (1965-89), and the PN is 901-211-683-00-OEM.

Since the shank has a hole in it, do not over torque as they'll snap in two, or prepare yourself and buy extras.

93Nav,

These pictures are extremely helpful. I know and understand exactly how it should go together and why. Thank you!