Turbo maintenance/refurb

darkhorse · 25 Oct 2019

Good to see some progress on this. Are you replacing the top mounts? with OEM ones?

Gazc2 · 2 Nov 2019

Tips back from the welders and fitted

https://youtu.be/91ft0BgPXko

Happy boy ðŸ˜

Gazc2 · 9 Nov 2019

shocks and lowering springs now back together with the right amount of washers ! also pulled the side skirts off these will be going to the painters with the rest of the aerokit.

darkhorse · 12 Nov 2019

Good progress GazC2. What remains on your jobs list?
My worklist keeps shrinking then growing :lol:

Gazc2 · 12 Nov 2019

I know what you mean

although your project is a tad more involved than mine as soon as you remove one thing something else catches your eye also been struggling for time lately so not progressing much so still on the list.

After removing the sills the clips that the screws go through are really rusty (will pop some pics up this weekend) so they are now on the parts list hopefully don't break the paint trying to get them off.

The front pair of support bars (silver) will be blasted and powder coated as will the pair on the back which are black don't like looking in the rear wheel arch and seeing the end of the bar all rusty.

I have 5 litres of transmission fluid to do the front/rear diff and gearbox so that job is next on the list I have still to purchase the liquid gold from opc for the 4wd controller (£60 a litre I believe)

Then its strip the front end to change rads/ac condensors and drier which I am slowly accumulating the parts so far I have drivers side Rad, center Rad and Drier I will be interested to see how good the fitting are on the pipes after seeing Pauls work in his thread on his 997.

Replace both Horns.

Full set of Michelin 4s,still got to purchase the rears and a new set of TPMS

Fit rear Aero spoiler,side skirts and Aero front splitter re-fit lower skirt on rear bumper

Fit cruise control

Get Geo done, code out spoiler and code in Cruise

MOT

Enjoy next spring/summer hopefully

bearing in mind I started this because the horn wasn`t working

darkhorse · 12 Nov 2019

Gazc2 said:
I know what you mean although your project is a tad more involved than mine as soon as you remove one thing something else catches your eye also been struggling for time lately so not progressing much so still on the list.

After removing the sills the clips that the screws go through are really rusty (will pop some pics up this weekend) so they are now on the parts list hopefully don't break the paint trying to get them off.

The front pair of support bars (silver) will be blasted and powder coated as will the pair on the back which are black don't like looking in the rear wheel arch and seeing the end of the bar all rusty.

I have 5 litres of transmission fluid to do the front/rear diff and gearbox so that job is next on the list I have still to purchase the liquid gold from opc for the 4wd controller (£60 a litre I believe)

Then its strip the front end to change rads/ac condensors and drier which I am slowly accumulating the parts so far I have drivers side Rad, center Rad and Drier I will be interested to see how good the fitting are on the pipes after seeing Pauls work in his thread on his 997.

Replace both Horns.

Full set of Michelin 4s,still got to purchase the rears and a new set of TPMS

Fit rear Aero spoiler,side skirts and Aero front splitter re-fit lower skirt on rear bumper

Fit cruise control

Get Geo done, code out spoiler and code in Cruise

MOT

Enjoy next spring/summer hopefully

bearing in mind I started this because the horn wasn`t working

That little lot makes me feel a lot better about my own jobs list :thumb:
Did you replace the top mounts or reuse the originals?

Indeed, definately a long list of jobs grows from a small one... I certainly feel your pain on that one!
Just wish I had a heated garage. It seems to have got rather cold at nights now... ah well; waiting on a new expansion tank delivered tomorrow then refitting the engine... again lol

Gazc2 · 13 Nov 2019

In regards the mounts I reused the originals I could see no sign of deteriation on the rubber inserts it was just surface rust on the metal so they got a refurb they are not overly expensive £70 a piece and also pretty easy to change if required.

darkhorse · 13 Nov 2019

Gazc2 said:
In regards the mounts I reused the originals I could see no sign of deteriation on the rubber inserts it was just surface rust on the metal so they got a refurb they are not overly expensive £70 a piece and also pretty easy to change if required.

I wish I was so thrifty

Would have saved myself a packet!. Makes sense though, they look in decent enough fettle. Just depends how soft the rubber has gone under load I guess but if they werent noisy then makes sense.
I checked my expansion tank for cracking before I refitted the motor and saw a few micro cracks (2)appearing in the usual place, even though the tank looked pristine colour wise (like new). Thought I might as well replace it now lol to save future work even though they were not full thickness, one of them didnt look far off

Gazc2 · 16 Nov 2019

These are the clips that the sill covers screw on to they all look as rusty as this one I don't like the idea of rusty parts direct to the bodywork so will replace these both sides.

Gazc2 · 24 Nov 2019

Managed to grab an hour in the garage this afternoon and got the front diff oil changed , as always try the filler plug first and it was bloody tight and took a breaker bar to crack it off, as other have mentioned that have done this the diff oil was clean as a whistle so all good and re-filled with 0.9 litre of nice new oil good for another 10 years.

Gazc2 · 30 Nov 2019

So managed to get the gearbox oil changed out today which like the front was really clean when it came out, I had ordered up a couple of replacement crush washers however there were none fitted when I removed the plugs both of which came out easily.I did fit the new crush washers.

Now after reading the trials of Grey996 and the unfortunate removal of the wrong plug just to be clear the filler plug is on the passenger side of the gearbox example pic below.

darkhorse · 1 Dec 2019

crush washers and o rings?

Gazc2 · 1 Dec 2019

No "O" rings pictures look a bit like o rings but its actually the thread on the plug :thumb:

Gazc2 · 1 Dec 2019

Removed the Turbo badge from My lid as this will be getting used on the Aero lid as these lovely bits of plastic are an eye watering £179

Gazc2 · 7 Dec 2019

One of the boys had posted his concerns over the corrosion he had found on his newly purchased 997.2 now some of the bits that are more evident than others are the braces on the front and rear subframes you can see the rear ones at the bottom of the liners in the rear wheel arch the front ones are hidden under the trays,the surface corrosion is no big deal it just doesn't look very nice so I will be getting the front one powder coated silver and the rears black to tidy them up.

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