ever seen this before? broken mount point for sensor bracket

jvandyke · 06:05 AM

broken block where sensor bracket bolt installs, missing spacer/alignment dowel
I assume there's supposed to be a spacer/alignment dowel in there and probably not supposed to be missing the corner.
This is a shot from a borescope, orientation off and bad quality but you get the idea.
Hoping to find a dowel or make one and get enough bite with the bolt to solder on.
I'm 90% sure the spacer didn't fall out on disassembly but will look around. Someone really tried to take things apart, the wrong way me thinks.
This explains the slop I felt in the bracket BEFORE I even tried to loosen the bolts. Silly POs.

picture of good bracket "borrowed" from JoshB (thanks)

jvandyke · 04:56 AM

And for your amusement:
sensor extraction; we didn't try very hard to get it out before pulling the bracket (good thing) there's no way they would have come out of the bracket in situ. Even on the bench I fought like mad to get the reference senser out, the speed sensor disintegrated and much is still in there awaiting more medieval methods.

jvandyke · 05-10-2016, 04:45 AM

any measurements of missing spacer appreciated, approximate depth most important, I think given the weak mounting point I'll want it to bottom out in the broken hole while still coming flush to the front edge of the bracket hole, or close. I'll take the bolt (to be renewed) and bracket to the hardware store and hopefully find correct OD and ID and cut to depth.

v2rocket_aka944 · 05-10-2016, 05:44 AM

that's an alignment dowel, not a spacer.
a new one "roll pin" of the same OD/ID/length is sufficient.

jvandyke · 05-10-2016, 05:45 AM

yep, sorry, wrong terminology

jvandyke · 05-10-2016, 09:18 AM

at least someone else has seen it.....
speed & reference sensor mounting

sixbanger · 05-10-2016, 05:40 PM

I fought one on a 944 once, What a PITA,

rojeho · rojeho's Garage

Ouch, I definitely feel for you. I am struggling with the same joy except my mount cracked through the reference sensor. Made it easy to disassemble. Looking back I probably would be time ahead to have just pulled the motor to replace the piece and not have to struggle so much with large hands and cramped quarters.

jvandyke · 05-10-2016, 06:14 PM

The location isn't too bad with a lift and two people. Just the stuck and broken bits are a drag. No luck sourcing a locating dowel at FLAPS, gunna hit "my" engine shop tomorrow. Heading out to double check it isn't sitting on the bell housing or something silly.

Arizona_928 · 05-11-2016, 01:23 AM

I would be tempted to get a new bracket. usually makes it worth while then fighting with a seized sensor.

jvandyke · 07:16 AM

The bracket is fine, the busted hole is in the block. I agree about the seized sensor, the speed sensor is 90% out after soaking, pulling, pushing, crushing, drilling chipping and scraping. Insane. oh, yes and burning, don't do that, makes it worse. I'm not even going to try to pull the aluminum sleeve. Hopefully the bracket is still able to be installed with sleeve and alignment dowel both in place, I read at least one thread where that makes it hard to install. Is there enough wiggle room for this? I highly doubt I'll get that sleeve out without destroying something. Have already tried tons of Blaster, heat, rubber mallet. Does the sleeve need to come out to install? This might be why the hole broke on the block, someone tried to force the bracket out with both sleeve and dowel installed?