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Cayenne74
Trainee


Joined: 13 Dec 2018
Posts: 59



PostPosted: Fri Apr 26, 2019 10:10 am    Post subject: Reply with quote

That's interesting the bush has made a difference to the take off. I guess if there was a lot of movement in it previously you'd be losing power through it on the pick up? I fitted a Poweflex bush to the engine arm on one of my old Alfa 166s with the 3.0 V6 Busso engine and can't say I noticed the difference apart the lack of it clunking!!!
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Fri Apr 26, 2019 10:43 am    Post subject: Reply with quote

I think my bush was just tired, so any replacement would probably get the same result, although I'm sure the powerflex is probably tougher than a standard replacement.

The centre of the standard bushing was slightly over to one side so it was past it's best. I assume torque was being lost through engine movement, now it is not which relates to the better response.
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6963
Location: Brighton


PostPosted: Fri Apr 26, 2019 7:24 pm    Post subject: Reply with quote

you often get a knocking noise when this part fails ..

I'm afraid i replace them but cant say what the benefits are as i'm not a driver as such .

i would assume it makes a difference though as you have pointed out .. there is a lot of sideways movement of the engine which this item is there to stop .

Just about to do a post on PDCC faults on these .. please read .
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Mon Apr 29, 2019 12:59 pm    Post subject: Reply with quote

Great post on the PDCC! I think you jinxed my car with the post as my chassis warning has returned. Doh!!

Last of the dirty jobs on this for now, well, until I work out what bushes need doing, wishbones or drop links.

I wanted to drop the exhaust as I noticed some leaking from one of the clamps (turns out that was loose), the exhaust flaps were stuck and most important, change the typical Porsche chocolate exhaust bolts for stainless ones and most importantly, get better access to some areas of the floor in order to waxoyl and protect.

Firstly, was to remove these exhaust sleeves, one had clearer been replaced recently as the bolts weren't rusty and this was the one that was leaking, the bolts were loose, I assume some heat cycling has caused that..



This clamp, someone couldn't be arsed to replace both bolts, one came off nicely, the other required my dremel.



The job of removing the exhaust looked easy, nothing was in it's way, so in theory, should jut drop down once the mounts were undone. only 4 mounts support the rear section, no under trays or supports, so nice and easy.

Everything undone nicely, managed to get it down but the problem came when trying to pull the tailpipes from the bumper, due to the height of the car, I just couldn't get a good angle, had this been up on a ramp, I would have had no issue. So after much banging and kicking around, I had to give in and remove the rear bumper cover.

Thankfully, this took a matter of minutes, 15 perhaps and I was happy to do this as it gave me a chance to see behind the bumper.

Once this was off, the exhaust was ready to hit the ground.





Once down, I could pull a few bits off to give full access to the underside in order for lots of wire brushing, drill with a wire wheel, all in prep for a range of products, area dependent. Stone chip, thick gloopy waxoyl, Dynax, hammerite, some silver and some lacquer. I did this first as I needed some stages to dry before being able to coat again.

No surprises, just minor stuff which wouldn't be a threat if left.





Went over most of the joins as this is where the factory sealent tend to split and let water sit.



Below, you can see the midle portion of the car is quite fresh but the back portion, muddy, surface rust on the subframes etc, so this was the area I wanted to sort out with the exhaust out of the way.



Mixture of waxoyl and stone chip


While that was all drying, I spent a few hours on the exhaust flaps, cutting off the old clamp bolts, cleaning the tips up and putting back together with stainless stuff.

First, I tested the actuators, I removed the actuator arms from the valve arms and used a vacuum pump, all was well, both worked nicely.



Once clamp bolts were cut off, the tailpipes were free! This would give me a good look inside the valve area. The tipe were left in a bucket of g101 after being blasted with korrosol to help remove the bulk of the carbon before the polishing wheel came out, annoyingly, I didn't take pics but they're looking like new now!! Will get some on the next detail.



Taking a look at the flap! Both were stuck in similar positions. Thankfully open.



Now this was something I reallyyyyyyyyyyyyyyyy wanted to fix but I wasn't successful. I soaked them in PB Blaster, WD, heated with a blow torch, freeze sprayed, repeated this and without wanting to apply too much force with hammers and pry bars, the shaft wasn't budging, I think in the end, I opened them more but probably through bending the butterfly.

I admitted defeat on this one, I'm happy that they're open and it isn't so loud that you would want it quiet, so it's fine by me. If anyone has any tips on how to free these, let me know but I can't think what else I can do..

I was a bit pissed off at this point so I didn't really take many pictures. I had painted the underside silver to tidy it up, refitted heatsheilds and started to refit. I regret not cleaning up the heatsheild as I normally would have but I was annoyed at the flaps and getting a bit tired, you can't see it anyhow but looking back at the pictures, I wish I cleaned it wack



Stainless coach bolts / nuts for sleeves



Exhaust back up, had given the mounts a coating of paint.



And that's it for now, the underside is now fully protected and cleaned.

It got a good wash and hoover the next day as it was pretty caked in pollen.






_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Fri May 03, 2019 11:29 am    Post subject: Reply with quote

Few jobs done last night, some fun, 1 not so fun.

Rained finally, got to see the protection on the paint working.



I'm investigating an issue I've got at the moment, I keep getting the 'Chassis system faulty' warning appear, it appears as soon as you hit 4mph. Resets once you turn the car off and back on but as soon as you hit 4, it's back and it seems to deactivate the PDCC..

This is the rear axle PDCC valve body, Demort has helped massively on educating me and anyone interested in what this is about. It seems scary at first but since I have been looking in to my issue, this is just a body with 2 pressure sensors and 2 motors. I refuse to buy a complete unit for £700+ when I know that the issue is going to boil down to a service or replacement of the components fitted to the body, I plan on trying to figure it out and hopefully it will save people replacing the whole lot, myself too.

So, with cover removed, here it is.



I wanted to check all plug connections and ideally, gain part numbers of components to find replacements.

After a dust down of the unit, I started pulling plugs and checking for dirt ingress/rust.

For reference, I found a part number for the pressure sensors and can source replacements for £22-30 each.





Bingo! I found rust within a plug, I got slightly excited at the sight, as this could be the cause of my issue..



After a clean with some tiny tools and IPA solvent, I buttoned it all back up.

Cover back on and replaced the original bolts with some stainless ones.



Tried it out and no change, warning was back. At this point, I'm going to get the code checked again and pay attention to the description before I start with new pressure senders.

TBC

I replaced the rear number plate lights with some LED versions, they were too bright, so I applied some tint film to tone them down.

Left tinted, right BRIGHT!





I noticed that one of the SMD tail lights wasn't working, so I set about the fiddly job of replacing it.

Desoldered and removed





String of replacements



For ref;



All working!



That's all!

Once I get past the PDCC problem, I'll do something a bit more exciting.

Did a quick photoshop of the roof bars removed and different colours on the wheels. I think I'll be sticking with silver. Roof bars, not sure I'm fussed either way.





This just arrived, new PDCC fluid tank, I'll give that a swap at some point.


_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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Cayenne74
Trainee


Joined: 13 Dec 2018
Posts: 59



PostPosted: Fri May 03, 2019 12:14 pm    Post subject: Reply with quote

If you don't want your roof bars I'd gladly buy them off you! I have a set of the Porsche roof rails for my car but I can really only fit 3 bike carriers on them whereas I need to get 4 on the car so am looking to swap to the roof rails with the Thule clamp on bars instead as they are wider.
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Fri May 03, 2019 3:50 pm    Post subject: Reply with quote

I'll keep you posted!

Was looking to see if something slides into the rail once the bars are removed to stop dirt collecting there, I have some black bars that runs down the middle of the roof too which I assume are stuck on..

Like this;

[img]https://www.design911.co.uk/uploads/images/product/Roof_racks/95504400062lr.gif[img]
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Tue May 07, 2019 11:14 am    Post subject: Reply with quote

I realised the MOT runs out at the end of the month, as I've got a baby due at the same time, I thought it best to get the MOT out of the way now and get some other eyes to look it over.



Everything was fine! I did mention that there is a knock from the front end but no matter what we pulled on, levered with a huge pry bar and push against, we just couldn't detect what was at fault. Either way, I plan to change the wishbones / bushes regardless, they have covered 95k so past their best I'm sure.



Outside of the MOT, I was able to poke around with it up in the air, quite nice to be able to stand up under it rather than be on your back! All looks good now that it has been cleaned.



The only thing I spotted was a dubious bandage over a section of an exhaust flexi pipe, I need to investigate why and what is involved here. I assume there is a split/hole here. At first sight, it looks like the primary cat pipe will need to be removed so that someone can weld on a new flexi but getting that pipe off looks to be a nightmare as the nuts have rusted in typical porsche fashion. Hopefully it can be done in situ, lets see. For the time being, I plan to heat wrap the flexi's, just to give some extra support in case they are getting weak.

So, the PDCC!!! I am itching to resolve the issue and I really need some better diagnosis but I'm impatient and had a new PDCC fluid tank to fit, so while I've got the bottle off, why not pull the rear valve block apart and take a look close at the components on it.

Fluid was pretty dark considering it was changed in May last year when a pressure line was replaced. The invoice for this job shows that the system was calibrated too.



New bottle as these have filters and should be done every 60k.

[

So, off came the 2 pressure sensors and 2 valves. Not much to it in essence, I was slightly scared when removing these as if something snapped, I would be in trouble, thankfully, patience, WD and winding the parts out by loosening and re-tightening ensured everything came out smoothly.

Nothing scary was discovered, I cleaned everything up and refitted. Now I know it is all clean and I have now refilled with fresh CHF11s, it's a step in the right direction. I will get it on a computer again and go from there. All I can do on it now is replace the pressure sensors, fine, that will be an easy and quick swap so that I've had them off but if it's one of the valves, I'm not sure what I can do as they are not something I have seen before and certainly not going to be easy to trace as no part numbers could be seen. I really hope they haven't died.



I was tempted to put power to them while off the car but I didn't know how much so thought it best to find out. As it's all canbus, I was unsure.





So, with it all cleaned, back together and new fluid, I had hoped that the warning wouldn't return, unfortunately, it did. I think the system will need a computer bleed so I'll get this done after a diagnostic check from a proper system. Demort, I'm coming!!

On a positive, the new fluid has resulted in a quieter pump, doesn't hum as much as it did.

Small job, I wanted to restore the original mats, they were an expensive option and tie in nicely with the red belts, the mats themselves are in great shape but some of the red colouring on the leather binding was coming away, so I bought some leather dye and touched in the wear patches.









More beading





So next, wrap exhaust flexi's, find out if the dodgy one can be replaced in situ if needed, more diagnosis on the PDCC and I reallyyyyyyyyy want to book it in to have the rust removed but I want to sort the PDCC first!

Oh, tried out a Goonies DVD in the rear.


_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6963
Location: Brighton


PostPosted: Tue May 07, 2019 7:38 pm    Post subject: Reply with quote

Oh blimey .. you are a bit further on than i thought !

Pretty corroded but its on the seat and not the seal so that's ok .

Start with the pressure sensors .. that's my hunch anyways .. solenoids .. well like any on the sports cars .. they block .. clean in petrol / paraffin or a solvent .

Fluid looks a bit black to be honest .. it should be pretty much green .

the pump is quieter .. hmm .. it shouldn't be in theory .. oil is oil .. perhaps some metal contaminants .. not sure there .

Either way .. replace as much as you can but to be honest most of it is in the reservoir so a replacement there will change most of it .
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My Daughter's Crowdfunding has hit the target see Here

Thank you all so Very much .



Mechanic

7pm - 9pm

Now At An Indy.
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Wed May 08, 2019 3:57 pm    Post subject: Reply with quote

Thanks Iain!

Ordered 2 sensors, lets see what happens. Also ordered an iCarsoft diagnostic thingy, hopefully I can then read all the codes myself.

If the sensors don't resolve the issue then it's got to be an issue with the valves but lets see!!

New fluid is much greener and has remained so, I will flush again when I fit the new sensors just to get some less mixed fluid in.

Voltage to the valves is something I want to find out and if they are earth through the body. It has a 2 pin connector, is 1 a live and 1 position? or 1 live 1 earth?
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6963
Location: Brighton


PostPosted: Wed May 08, 2019 7:49 pm    Post subject: Reply with quote

diagram is on the pdcc post .

its a return system so voltage / earth supplied from the control unit from what i've seen on the diagram .
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My Daughter's Crowdfunding has hit the target see Here

Thank you all so Very much .



Mechanic

7pm - 9pm

Now At An Indy.
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Mon May 20, 2019 11:57 am    Post subject: Reply with quote

Odds and sods going on and more recently, having my patience tested!

Looking good from this angle!



new EL strip for the passenger side sill arrived, this was an easy enough to do job

Before


After


While poking around, I discovered the car has the expensive bearing support upgrade.



Gearknob handle was scratched, was going to paint this but then decided to use some spare alcantara to trim it, this was a bit trickier than I thought but after an hour, made a nice improvement.







Brake pads were very low and I had the wheels off to change the wishbones (or so i thought) so changed the pads





New pads and fitting kit


Now, the job I wanted to do was change the front lower wishbones but I just couldn't get one of the bolts out!! It undid and was turn, along with the bush but as it had seized itself within the bush sleeve, I couldn't bash it out. Not being able to get a good angle on it didn't help, I tried heat and all sorts. I'm going to attack it again this week but just cut the bloosy thing off once my replacement bolts arrive.





I have since ordered new alignment bolts and upper wishbones..

Can't wait! Dont know Mad
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0

Last edited by MarkGolf on Fri May 24, 2019 8:52 am; edited 1 time in total
 
  
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Cayenne74
Trainee


Joined: 13 Dec 2018
Posts: 59



PostPosted: Tue May 21, 2019 7:59 pm    Post subject: Reply with quote

The garage who did my lower wishbone had exactly the same problem as you. Front nearside bolt came off no problem but the other side a complete pig apparently and poor access. Think they said the access hindered them cutting the bolt off. They free'd it in the end but it took an extra couple of hours, hence more of my money! Hopefully your second attempt proves more fruitful.
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Wed May 22, 2019 11:53 am    Post subject: Reply with quote

What a nightmare, seems common after doing some google searching on how people removed it.

I'm awaiting new nuts/bolts to arrive at Porsche, once I have them, I will have a go at cutting the thing off!

New PDCC pressure sensors arrived, easily fitted those in 5 mins.





Not sure if they resolved anything as I'm getting the Chassis System Warning when I turn a corner, once my wishbones are sorted I'll get that code checked as that may not be PDCC related.
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Tue May 28, 2019 12:39 pm    Post subject: Reply with quote

Always nice to start with something simple...






Got the bloody wishbones off.





The ball joints were good, totally solid still, I was really surprised by that but the rear bushings were showing splits and felt soft so this was a worthwhile job.





Really heavy, I regret not going for the Q7 aluminium arms, not that I'm going for weight saving here but I'm sure it would have added some benefit.



Ran out of time to do the uppers but I'm hoping to get those done this week along with top mounts which I only just discovered are available to buy for the air shocks.



All of the entry guards are scratches, so I set about cleaning those up as a little job on free moments of the bank holiday.





I didn't go for perfection as I didn't have the right bits with me but I did the best I could.




Front upper arms, top mounts and gearbox mount next! Will finish up with an alignment too, then I think that will be it for a little while as the baby is due anytime! bye Dont know
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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Pops
Silverstone


Joined: 15 Jul 2016
Posts: 106
Location: West Sussex


PostPosted: Tue May 28, 2019 12:47 pm    Post subject: Reply with quote

Good work! thumbsup
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Remapped by Celtic Tuning.
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Wed May 29, 2019 10:46 am    Post subject: Reply with quote

Cheers Pops!

Need to PM you about what you do Wink

Just a quick lunch time job

New AOS diaphragm turned up, no reason to change this other than why not for the sake of £25. My 997 benefited from a new AOS so I figured, why not on this.

10 minute job, cap takes some careful levering, popped off to show oil build up from vapour. Cleaned this out and put new part in.

Not expecting 100 bhp but at least it's one extra thing to future proof it. Signs of a bad one is smoke on start up and hissing noise, I had neither but many people on the US forums get this around my mileage/age.

Original diaphragm was brittle as anything, in fact, I think it was stuck in position so probably wasn't doing it's job.

Overnight parts from Russia









_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Fri May 31, 2019 8:49 am    Post subject: Reply with quote

Typing this with lots of aches and pains today, spent a solid day from 9am up until 10pm fitting the upper wishbones, new top mounts, doing some rust prevention finished off with a wash.

I lost an hour just doing this! I just couldn't get one of the wiper arms off and my bearing pulley was too big! Eventually got it free after lots of WD40 and pulling.

Removed the scuttle just to gain access to one of the turret mount bolts, also cleaned out leaves and crap.



Arch liner removed



Shock out, I never thought I would be pulling a shock out of this car, the air system has always scared me as it's an unknown but now I've done this, it's fine!



Many people don't seem to know that there is a rubber mount in here, after seeing a guy on Rennlist showing his one torn in half, it was a no brainer to change while I had the shock out. I had a knock coming from somewhere so I would have hated to only do the wishbones and find the knocking is still present.

Upon inspection, the mount was fine, I couldn't tell it apart from the new one, the upper wishbone looked good too, balljoint was a little loose but I wouldn't have said it was at the end of its life. I was slightly worried at this point as I didn't find the destroyed bushing/joint I was hoping to see.. Drivers side anyway...



When I got to the passenger side, I found the fault, the balljoint was floppy and knocking!! What a sense of relief that was worship Bandit Thumb



Old and new



The passenger top mount was showing some signs of age too with a healthy crack, I wouldn't have said this was bad, probably just cosmetic at the moment but I like to future proof while I'm working on an area.





Gave a quick clean up



New upper wishbone, these weigh nothing, I really really wish I did the ally lower arms!



Geearbox mount was next!

Original was squished



I removed the entire arm, 8 bolts and dead easy.



Smashed the original bushing out, this was very easy..

The hard bit was getting the new one in! The bushing was larger than the hole it had to go in, there was NO WAY it was going in. So after a good hour of sanding the edges of the bush and the bracket down, eventually, the new bushing was fitted after much lube, tapping and hammering!



I can tell it tested my patience as I didn't take any more pictures Rolling Eyes

Time to relax from working on this at every free moment now while I enjoy my son coming in to the world any day now. The next jobs will be alignment, wheel refurb and paintwork so nothing for me to get so involved with Thumb

As for how the car is now, the knocking is no more and the drive is smoother, I was getting a light vibration at 33mph, commonly reported online and the driveshaft being the cause, as the bearing support and doughnut are new on my car, it couldn't be those, hence spotting the saggy mount. The vibration has gone. So I am very happy with my efforts Very Happy
_________________
Current fleet
1991 964 Carrera
2005 997 Carrera S
2008 957 Cayenne GTS
2003 Boxster 2.7
1994 Eunos Roadster S Special Turbo 270bhp!
1991 Mercedes 500SL
1979 Mercedes 280e
1995 VW Golf VR6 3.0
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 715
Location: S.London


PostPosted: Mon Jun 03, 2019 9:23 am    Post subject: Reply with quote

Got my alignment sorted, I thought I would give Kwik Fit a go, not somewhere I have ever taken a car before but since they had the highly regarded Hunter machines and they were local, I thought what was the worst that could happen..

Got there first thing Saturday morning and after a short wait, it was up and being adjusted, everything needed adjusting but it didn't take the guy long.

Once he said the adjustments were made, I compared them to the Porsche specs and everything was spot on!



So £85 for 4 wheel alignment, nice guys and local, all good!






bye
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6963
Location: Brighton


PostPosted: Mon Jun 03, 2019 7:49 pm    Post subject: Reply with quote

The Hunter system is pretty damn good .. we had it at OPC .. it basically holds your hand .. it tells you what to adjust .. foolproof really so i have no problem recommending Halfords to do a job like this .

Cheap as chips and the same job as an OPC could do .
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