Flapper Boxes.
 

This is my first post and may I say that during the last two years spent bringing my ’86 3.2 litre Carrera Coupe up to scratch I have been assisted on many occasions by reading through the solutions to problems contained on this site.

One of these problems was the replacement of the flapper boxes. To put it bluntly mine were shot, completely rusted through and useless. To avoid snapping one or more of the six studs holding down these boxes I elected to use a small nut cracker instead of a spanner to remove the badly corroded nuts. I had already removed the engine and gearbox for other work, allowing easier access.

http://forums.pelicanparts.com/uploa...1402360294.jpg

Counter holding the tool is essential as the wedge is driven in. Very satisfying to hear those old nuts pop off!

http://forums.pelicanparts.com/uploa...1402360975.jpg

Old boxes removed and threads cleaned up.

http://forums.pelicanparts.com/uploa...1402361154.jpg

The old versus the new

http://forums.pelicanparts.com/uploa...1402361317.jpg

Nothing like new boxes and hoses!

The nutcracker used was that able to handle nuts of 3/8 to 1/2 inch or 9-12 mm in size.

This method worked very well for me so I pass it on for what it's worth.

Cheers all.

Nice job. I have to do this sooner or later. Going to try and save my boxes first. I don't know how bad they are though.

I've got some boxes for sale that I just posted, I restored them.

I saw your ad. They look good!

Nice Job - you're good for a long time.

WELCOME by the way - please post a pic of your baby.

THanks for posting, very timely. I was going to torch these off with oxy-mapp.

http://forums.pelicanparts.com/uploa...1402368810.jpg

Yeah I like the nut splitter idea. I wonder if that would work on exhaust nuts.

That's a clever application that tool.

http://forums.pelicanparts.com/uploa...1402370921.jpg
Thanks for the welcome Dan.

After two years of work followed by a full respray in original colour I now have very little left to do, except enjoy driving the beast!

Drive it man - she looks great with the tail too.
I need paint someday.

I'm curious, did you old boxes have a rubber cap at the end of the cable to keep out dirt and moisture? I just re-furbished mine and would like to replace the cap but I don't see it in the parts diagram. See photo here:

http://forums.pelicanparts.com/8108464-post157.html

Also, in your third photo there is an extension piece coming out of the old box on top. This piece is shown in the parts diagram, but was not present on my car when I removed the boxes. Does anyone know what function it serves? Does it simply prevent the hose from dropping down on something?

frankc------I have also searched for the rubber cap you mentioned but have not seen it listed in any parts diagrams.

The extension piece exiting one of the boxes is the temperature probe for the automatic heating system. From memory the auto heat system was incorporated in cars manufactured from 1984 onwards.

Gentlemen,

Pelican has the rubber grommet for the heater cable guide tube. They have 26 in stock.Pelican Parts - Product Information: 914-504-319-00-M100 Product Information: 914-504-319-00-M100

Flapper Boxes
 

81SC------thanks for that. My search was obviously not thorough enough!

I think they are beyond my "10 Steps Program... http://forums.pelicanparts.com/porsche-911-technical-forum/589980-cleaning-flapper-boxes.html

I used a Dremal tool with a flexible shaft and good fiber re-enforced cut off wheel. Cut a slot on the side of the nut, once the slot was cut a small chisel hit in the ccw direction would break it loose. When loose I was able to use a socket to remove.http://forums.pelicanparts.com/uploa...1402407356.jpg
http://forums.pelicanparts.com/uploa...1402407384.jpg

Terry

Where did you get that tool from?

This one below looks different, any idea which style is best?


Craftsman Nut Cracker
Sears.com
http://forums.pelicanparts.com/uploa...1402413277.jpg
The smaller nuts like on the bumperettes and other bumper rubber have snapped on me. Smaller than 3/8" would be nice too, something down to 1/4" or below 8mm.

Where did you purchase the "orange" hoses? Thanks,

Bob

They are available on Pelican here.

Not sure how they're different, but there is a different P/N for the '87-'89 Carreras:
P/N 999-702-154-40-OEM

I noticed the end of the guide tube was flared in the picture of the new boxes. Perhaps this 999 part number is for the flared style?

I just ordered two of the 914 part numbers since I have the non-flared style and that number is what is shown in the parts diagram for my '77.

wrxnofx -

Thanks for the Pelican "here" link -- my question is that when I pull up that Pelican link, there are no pictures of the Genuine Porsche Brand parts. Also, there are two parts listed, so I did not know if the heater hoses are "orange" on the outside, just like the original ones on my car, or are they orange on the inside and whitish on the outside?

Bob

I see what you mean, Bob. I can't really tell, either, since the Porsche OEM ones don't have a picture.

The non Genuine Porsche part has some type of white fabric over it. It is difficult to see in the catalog photo, but see picture 5 in my following post for a better view:

http://forums.pelicanparts.com/8106677-post152.html

Flapper Boxes
 

kach221,--------There is no reason why the Craftsman tool pictured in your post should not work as well as the one I used except for one thing,------it may be too hefty to fit into the space between the outside of the nuts and the flapper box body.

The dimensions of the splitter I used are as follows:-

Length (excluding wedge screw end)-------2.4"

Circular head outside diameter--------------0.87"

Circular head inside diameter----------------0.54"

This was the smallest splitter included in a set of four purchased from "AUTOTOOLS", a company based in Victoria Australia and from memory I could not have done the job if the splitter had been any larger.

Their products can be viewed via their website:-www.autotools.com.au

Best of luck,

Don.