Most Annoying/Frustrating/Maddening Design/Assembly Feature of 924/44/68 Family?

[jjeffries]

This idea just came to me. Please add yours, we'll likely learn something as the Sages in our midst laugh then tell us a solution or three.

I suppose an alternative title for this thread could be "List the Reasons there are so many dead 4 cylinder transaxle Porsches in gas station parking lots"

Here's mine:

The fact that you have to go under the dash to disconnect the ECU wiring harness in order to pull the motor, THEN WORSE, when you try to reinstall your car's engine, you have to go back in there to guide the sumbeetch back thru the firewall.

You must have your own favorites? Please post some, if only from the Misery Loves Company angle.

cheers,
John

[Ernie944]

The worst for me was changing relays & fuses on my 83-944 ....you got to be a Pretzel with arm has long as a gorilla & fingers like a Fairy ,was glad when I got my 968.

[9FF]

The Fritz who designed the distributor cap fasteners should be shot as should the Hans who chose the adhesive for the rear hatch glass.

[Jfrahm]

Rubber center clutch disk, Auto trans flex damper, 968 DMF. I suppose the DMF is common these days but I still don't care for it.

AC low side port down by the compressor. Thanks for that.

[Fast Freddy 944]

Timing belts for the turbo car, pain in the kazoo. Access to the clutch. Turbo location., getting to the alternator on the 951, guage issues, the rubber hockey puck dampener on the clutch, noisey rear ends. But you know, its the nature of the beast, Im pleased with the cars performance, its looks, and its life span, it seems to keep on ticking. Great exotic sports cars. I think if somebody has issues that turn violent against a designer, they might need to sell their car and buy a Toyota. Porsche kick butt! Great entry level car!

[v2rocket_aka944]

It's way easier to unhook the harness from the engine And leave the wiring in the car...i don't know why people **** around trying to pull the harness from the chassis.

The distributor cap fasteners are easy if you get a 6" screwdriver and bend the shaft 90 degrees.

I think it's silly that they used a pull type clutch (pita) and a tiny baby miniscule radiator (944 rad is same overall dimension as first gen Golf).

The early fuse panel is terrible.

But my biggest gripe is that Porsche used an AFM when MAF technology existed already... the cars could have been so much better had they spent the bucks.

[jjeffries]

V2: I did that because Clark’s instructions were written thusly. Other items I’ve thought through and done my own way but this wasn’t one. Your sentiment is a bit like how I feel when people use Navi, going via some preposterous route because they didn’t (wouldn’t? couldn’t?) read a map, and/or have any sense of direction. If I do this again I’ll know better, but it’s good you’ve pointed out a better way ... as I wrote up top, that kind of feedback was a goal ... in addition to just venting.

Thanks, John

[SilverLined]

I've found that Clark's instructions occasionally omit some key info. I don't mind, as it keeps me honest, and reminds me not to take the wealth of information he did provide for granted.

Case in point, the early dash removal job. This is a fiddly one, and there are lots of mystery bolts. Most are found with little effort, as they're logically placed. Except for one stupid screw. This is where a tip would've helped, and likely saved many a trim piece...

In their infinite wisdom, Porsche engineers decided abandon the top pre-molded screw-hole in the A-pillar trim pieces, whilst using the middle and bottom ones. This is confusing for a first-timer, as most will assume that the "missing" screw head had been sheared off/lost in the past, and glue or butyl had been used to put it back together. In fact, there is a screw in there, somewhere (look up and in, and dig around). You may get lucky and find it, or you'll see it after you've bent and warped your original trim piece beyond repair.

So for me, the hack-job factory placement of the top screw of the A-pillar trim makes the list!

[Mr. Squid]

Originally Posted by 9FF

The Fritz who designed the distributor cap fasteners should be shot as should the Hans who chose the adhesive for the rear hatch glass.

Fantastic Response! I hate the lower dist cap fastener, and the adhesive for the glass lasted a really long time, but it is amazing that after all the improvements in adhesives that there isn't a good solution.

My other gripe is that you cannot swap the torsion bars or adjust them if they are a tooth off without lowering the rear suspension from the car!

Or that welded on Nose panel between the headlights on the early cars. Why wouldn't a piece like that bolt on when the majority of accidents are to the front of a car? At least they changed it to a bolt on piece later in production.

[azbanks]

The idiot who decided to place the AC hardline connection at the firewall right behind the cam box/head. To swap that line requires 8 inch fingers with 12 joints or pulling the engine/head.

They could have moved it 5 inches toward the drivers side and had plenty of room but no, they had to put it in a spot that is inaccessible.

[Stoneguy]

The fuel lines running directly above the red hot exhaust header! Brilliant!

[azbanks]

Originally Posted by Stoneguy

The fuel lines running directly above the red hot exhaust header! Brilliant!

Yes, of all the dumb ideas, that one has probably killed more 944's than any other.

[911tracker85]

don't get me started ....

all of the above plus some, but my mind is protecting me from those horrific memories....

but then I get in my modified 951 and take to the back roads and all is forgotten.

[Fast Freddy 944]

I never heard of any 944's blowing up due to fuel line placement. I seen Ford, Chevy, Dodge, Honda, tesla and other cars burning to do electrical issues, but no Porsche 944 issues, Interesting..

[OK-944]

Not the best choice for fuel line placement...but from where I sit - it seems that problems only arise when these lines get old and start to crack, and/or when older lines get twisted about during removal and re-installation and develop cracks in the process, and/or get reinstalled incorrectly. Proper insulation is also a good idea - although, ironically, it is this insulation which can sometimes hide underlying cracks in older lines. Probably not a good idea to even think about re-installing thirty plus year old fuel lines (especially those in the engine bay)...just bite the bullet and install new ones!

[OK-944]

oh...yeah - gripes. Here's one - that tiny nut on the upper left rear of the alternator rear cover...locating and reaching this from underneath? - grrrr! And what about that upper left torque tube to bell housing bolt? - aaarrrgghh! The serious lack of front of engine clearance - getting that drive shaft to disengage/re-engage with the pilot bearing...especially painful when attempting a single handed engine removal/installation? - ouch! Not sure if any of these are design "flaws" - but PIA's nonetheless!

[v2rocket_aka944]

Originally Posted by Fast Freddy 944

I never heard of any 944's blowing up due to fuel line placement. I seen Ford, Chevy, Dodge, Honda, tesla and other cars burning to do electrical issues, but no Porsche 944 issues, Interesting..

Old fuel lines and cracked fuel rails have claimed hundreds of 944s over the years.

[Ernie944]

This pics tell it all about owning a 944

[mytrplseven]

Oil filter changing mess. What a joke!

[WolfeMacleod]

Originally Posted by 9FF

The Fritz who designed the distributor cap fasteners should be shot as should the Hans who chose the adhesive for the rear hatch glass.

This. I have both a 924S and a 968. Both should have the rear hatch frames re-done. Nobody around Seattle can or will do it. And I certainly don't want to.

What was that original adhesive? Do we know?