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Ernie944's Avatar
 
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Location: Caraquet N.B Canada
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Let us know when the motor back in & send the biggest pics you can of the job done.Take care & be safe when installing it back

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Caraquet,N.B. Canada.
Old 10-15-2020, 07:54 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #401 (permalink)
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Merci bien Ernie, thanks Bob and Patrick.

The car is on a scissor lift and the engine is on a lift table, a bit overkill in terms of adjustability, but we’ll see.

Just now I realized I didn’t have a clutch alignment tool; in the past I’ve used a deep socket and masking tape to get the right OD but for $5 it’s be goofy to thusly bugger around so my local CarQuest has one coming tomorrow morning. My back could use a break anyhow. Hopefully with the clutch perfectly aligned and moly grease on the points of contact, it all slides together with the gentlest of touches ... “like buttah”

This morning I took the SC to return the valve spring compressor to Steve, one of my pro mechanic and dealership veteran friends. Bright blue skies and peak fall colors; we’ll be complaining about the winter soon but New England is a great place to live.

John
Old 10-15-2020, 10:12 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #402 (permalink)
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Of false economies and extra parts orders...

When I removed the original engine, I did so by dropping it with the cross-member and steering rack. This means that I also removed the suspension control arms and sway bar.

The right control arm was clearly bent, but the left one looked good and even retained its 2/87 date stamp. Viva originality ... and frugality ... so even though a new Lemfoerder arm is just $20, I only ordered one, which I built up with new bushings and a URO ball-joint yesterday. So far so good.


This morning I came to regret that fiscal austerity.

First, I removed the sway bar bushing: cut one side off with a hacksaw and pushed out the remainder, then the front bushing, using threaded rod, large washers and big socket ... some considerable force required to move that one.

Then, I went to remove the big/rear bushing, and this was when started to wish I'd bought TWO new control arms; the bushing was a swine to remove and once I'd finally hacked it off, I found that someone had been in there before me and ruined the arm:


To avoid having to press a new rear bushing on (as I will need to do), the previous guy had ground off a serious amount of the arm's pivot/shaft end, such that my new bushing wobbled loosely on it ... it's meant to be firmly located and under tension, IIRC.

Out came the phone to find a replacement ... surely easy since these are actually VW parts? No: the VW's they fit are likely now rarer than 4 cylinder Porsches, so it's not exactly a fast mover. The big mail order house in southern Connecticut had stock ... cool, a 1.25 ride each way would be worth it. Nope ... they are still not allowing in-person will-call pickups, and can't say I blame them. So a new arm is coming from them, next week. And ... here's hoping I can uninstall those two bushings from the bad arm ... I didn't even think of that when I ordered the arm.

I can certainly get busy with the engine/crossmember in the meantime. But the lesson for others here is: how much is your time worth vs. $20? Date stamps be damned!.

John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 10-16-2020, 07:55 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #403 (permalink)
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Hey John,
I performed this job a few years ago and ended up just replacing everything from the arms to all the bushings, as well as the ball joints. I figured that the old 30+ yr rubber material had enough; some of it looked ok but there were small cracks and dimensions were a little skewed when mic'd...
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1984 944 NA, constant tinkering
Old 10-17-2020, 05:57 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #404 (permalink)
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Quote:
Originally Posted by jjeffries View Post



... and 196,000 isn't a particularly important number, but it's fun to see the odometer doing its thing. I need to send this gauge away for repair, because not only is the trip meter broken, but the speedometer is in urgent need of recalibrating; it shows a real 80 as being 60mph. I've figured out what RPM's in 5th equate to certain speeds (23.2mph/1000PRM). But it's best to keep everything working properly, so I'll try to remember to ship it to Palo Alto Speedometer once the car is tucked away for the road-salt season.

John
Hi John, Good idea to fix the speedometer this winter. Maybe we'll get no snow in Connecticut and your 911 will be a 4 season car?

My speedo is off too in the 944, but it reads 8mph higher than actual - so opposite of what you're seeing on your 911. The odometer doesn't work either. I know the gear on the odometer is a pretty easy fix, but have no idea how to fix the speedometer so I'm thinking of sending the gauge away also.
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Old 10-17-2020, 03:55 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #405 (permalink)
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Greetings All ... I've been beavering away on this project. I started the engine installation last week, something of a dance between the engine/crossmember and the rest of the car as the engine has to be threaded on its vertical journey, front to back and front again, to clear obstacles on the way.


This is a job where one would be much better off with a two-post lift than a scissor version like mine; maneuvering the engine, on my HF 1000lb lift table, within the available space provided by both the car and lift itself, was tricky.


If I had to do this again - and I sure hope I won't - I'd spend more time leveling the engine/crossmember assembly on the lift table as I was placing it there with the engine crane; I had it too nose-down and had to do some levering and blocking with those little bits of 2X4's we all keep at hand to get it properly aimed at the driveshaft splines.


I nudged the crankshaft forwards in small increments in order to enable the clutch disk and driveshaft splines to make their acquaintances.


Yes, this would likely have been easier with a second pair of hands, but I needed to get it done solo. With some grunting and choice epithets hurled in the engine's general direction, eventually it was in.


So now I'm in the mode of methodically getting everything hooked back up. Today I used my time/backache-budget getting the A/C compressor fastened to its bracket; what a PITA. I probably should have grabbed the 2" air grinder and taken a hair of the bracket's attachment lugs to make the fit one with no interference... I see no reason for it to be quite so tight.


With the engine back in, I was looking forward to using those new control arms and getting the car back on its wheels. But you wouldn't want to put the arms back on without the sway bar that links them. I went to my stash of new parts but quickly found that what I had on hand - as specified by PET, 477 411 053G - would not work. Why? The inner diameter - where the bushing fits around the bar - was fine, but the outer diameter, where each bushing sits within its bracket, was too small (35mm OD vs the required 40mm). So what do the original parts look like, and do they have a P/N on them? A. They have the correct dimensions, and B. 951 343 794 00. These, however, aren't readily available, at least from what I can tell.

As described in the thread I found (and bumped), this is a known issue for the 924S and certain 944's with the 20mm front bar. The 944-specialist shop in FLA is the only vendor I've found who acknowledges the (numerous) different sized front sway bar bushings available; I'll follow-up with them tomorrow.

You may be wondering, why not just re-use the original 951 343 794 00 bushings? I would, but while they have the same p/n molded into them, they are two difference sizes Huh? Yes, one is approx. 10% larger, the result, I submit, of having swollen from ATF/Dexron leaking out of the Power Steering system onto the sway bar fixings.


The 924S is a funny old thing in terms of the odd collection of parts from which it was built, some things new, others old, some borrowed ...

As I wait to obtain the correct parts, I'll continue the reconnecting and plumbing. Believe me, I'm wondering if the engine will fire and run right out of the gate, or will it fight me?

John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 10-25-2020, 01:10 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #406 (permalink)
 
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John,
Please have the video cam running when you get to that point!
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1984 944 NA, constant tinkering
Old 10-25-2020, 05:19 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #407 (permalink)
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Quote:
Yes, this would likely have been easier with a second pair of hands
someone posted on my thread they thought this was impossible without help.

good job.
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Bob Cox
84 928S, Ruby Red linen/brown interior - preferred DD
87 924S resurrect and gut and another track car...
86 944 turbo my new DE/track car.
78 930 clone project car.
Old 10-26-2020, 06:12 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #408 (permalink)
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Originally Posted by 911tracker85 View Post
someone posted on my thread they thought this was impossible without help.

good job.
Bob,

That’s kind of you but I imagine guys who do this for a living get them done by themselves with relative ease. If you had the car on a proper two post lift and the engine assembly on a good table, ideally about 3’ tall, it wouldn’t be a big deal.

I need to check the Engine Conversions forum to see how your LS > 911/930 is coming along.

Best, John

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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old Yesterday, 08:15 AM
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