Drive Train Upgrade, S to S4: Project Thread Blog

[Pete R]

Originally Posted by whiteNSXs

Pete,
I think we are talking about different subjects here. Although the front track remain the same as you pointed out, the steering geometry has changed due to the steering pivot is now more INWARDS so the axis intercepts the ground more inwards too. The older car can use 50mm offset front wheels as I see that Landseer has Turbo Twists. However, with the suspension swap, his front wheels will need to have 55mm+ offset to maintain the negative scrub radius given stock ride height. The Turbo Twist is ET 50mm so it is not optimal after the swap unless he lowers the car and dial in less negative camber. Anyway, Landseer indicated that he would like CIII wheels which are 57mm ET and would fit just fine on the new set-up regardless of ride heights. 16x7 stock wheels are et 65mm, I believe, so they also work fine.
Cheers.

ahh, okay, I see what your talking about now. I use an 8.5 wide @ET55 and they seem to work okay

[Landseer]

Good information here, thanks!


Am watching for the Carerra III's.
They look perfect on your white car.

[MPDano]

You make pulling the Tranny easy. Closely watching your project.

[Fixer]

Originally Posted by MPDano

You make pulling the Tranny easy. Closely watching your project.

Agreed. Great wrenching!

[Landseer]

The transmission removal is pretty straightforward. I've done a series of these.

The front suspension swap is a time consuming endeavor.

[Landseer]

Moving into reassembly phase.
Still need to find some bilstein specific adjuster collars, as shock install is pretty much first on the list.

While waiting.

New bearings for front hub

[neil30076]

Chris, nice work, I wish I had taken the time to photo shoot all my work ( like Leo - Dano - does) . Maybe the next major task i undertake i will, seems like all mine are electrical troubleshooting or harness rebuilds, or its been done before, , and i get so preoccupied in the task i forget the camera.

[AirtekHVAC]

I usually get too greasy to want to touch the camera...then I regret it afterwards....then I repeat the cycle the next project..

[Landseer]

Inner tie rods are shorter for S4.
Could probably shorten the S ones, but they have countless miles on them.
I bought a set of S4 inner/outers to swap.

Tried to remove them in-situ.
Too tight, risky, could damage rack.
Removed rack to manage this swap on bench using vice to contain the counterhold wrench.

Also, stabilizer bar links are longer for S4.
Those get swapped too.

Also, stabilizer bar itself is different for S4
Diameter same, but ends have a different angle.
So it gets swapped along with the links on each end.
(Not sure if the S swaybar and S links would fit instead of the S4 set / they might also)

WSM does a good job of pointing out differences between S and 86.5 (they call it 86)
I'm calling it S4.

Nothing but carnage so far tonight. Wife is pissed at the ever-expanding mess.

[Landseer]

Looking ahead, Antilock is going to get interesting.

Rear axle counter gears are different.
Front hubs with counter gears are different
Sensors are different
Bias valve on Euro is 33 bar, which I'll retain over the 86.5 unit which is 18 bar.
Pumps are the same.
Harnesses are different from each wheel to brain.
Brain is different.
Not sure about Brain plug side of harness and the wires leading to the CE panel.
CE panel has a position change for the panel-mount relay and different fusing.

Last part will be a challenge at the CE panel and leading to the brain.

[Jadz928]

Chris,
Great documentation! You have really taken my old Chewy to the next level.

[Fixer]

Nice work! and nice press, where did you buy?

[MPDano]

Originally Posted by The Fixer

Nice work! and nice press, where did you buy?

Looks like my Harbor Freight one.

[Pete R]

lol, I have the one that is an "A" frame...for what it cost for a shop to press a couple bearings you can buy a whole harbor freight one.

[Landseer]

Exactly.
Except mine isn't square. Needs a few bolt holes elongated, application of a square, and my neighbor's welding gear.


I just bought replacement nuts for my front bilstein shocks. $95. Each.
Those were expensive cuts I made.

[Mrmerlin]

Ouch on the Bil nuts
FWIW you should heat the hubs prior to installing the races
races go into the freezer,
install the small race first,
then the large as it will usually fall out
a press isnt necessary

[Pete R]

Originally Posted by Mrmerlin

Ouch on the Bil nuts
FWIW you should heat the hubs prior to installing the races
races go into the freezer,
install the small race first the the large as it will usually fall out
a press isnt necessary

+1 I've done it.. very effective. Since my wife wouldn't let me use the oven, I bought a single burner hot plate at Wally Mart.. works great

[Landseer]

I've been given this advice before about the bearing races.
Used my gas grill to preheat hubs.
Took a phone call prior to install, hubs cooled.

Will use that advice on the next set, along with freezer.


Meanwhile, axle boot kits are on-the-way from Roger.
Mark is sending new Bilstein adjusters.

Suspension assy completion target is Thksgvg.
Prior to that, some interior work and harness transplants.

[Landseer]

Yes, this used to be Jim Doerr's car!
Somewhere I've got a picture of him with it about 10 years ago.

Some evidence of progress.

Rack reinstalled with new tie rods.
S4 Sway bar and links
Rebuilt upper control arm
Awaiting shock adjusters, then rest can be reassembled.
Oh, and I have a set of front fender well liners from the 86.5.
Might need to cleanup the wells and mount them later.




The patient, anxious to run




Gotta fix the torn rear boots that came on the 86.5 axles.
A few timing belts, too, for future project work




86.5 axles and hubs with some spacers.
Need to remove the big axle nuts today.
Am going to try to get the rotors resurfaced.
Just enough wear and pitting to be worth trying that, but not worn too badly.





Antilock brains. 86.5 vs 84. Same case, same connector (not sure about the pin outs yet). Different programming.

[Landseer]

Throwback shot. Lifted from a Polaroid

Same patient

84 Euro car dubbed "chewy" for his odd in-dash sounds.


The formative years of resident 928 historian and owner of Press Release 928's #1 and #6.

Looks like a grad student ready to hop into a TR3 and light a pipe on the way to class, skirted college coeds all around.
(Video from J Geils "Centerfold" comes to mind for some reason.)

http://www.youtube.com/watch?v=BqDjMZKf-wg