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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2960
Location: North East England


PostPosted: Sat Jul 08, 2017 9:46 pm    Post subject: Reply with quote

Unusual problem this weekend. The lower gearbox mount lug pinged off as I was setting off from work. I heard and felt it, thinking it must have been one of the new coil springs cracking. When I checked I found this:







What an absolutely terrible design. The thinnest bit of alloy fin is used as the gearbox mount lug!

Anyway, I was puzzled with what to do as a solution. Fortunately a friend gave me the number of a mobile aluminium welder - a rare breed!



Access isn't as bad as you would think and within an hour he had built the area up with new weld to strengthen it and got it fixed. Hopefully stronger than new!




Looks like its fixed, tomorrow i'm going to attach it back onto the mount and see. £65 for a job which could have saved me £800 for a second hand box!

Result!

Thumb
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986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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kas750
Paul Ricard


Joined: 31 Mar 2013
Posts: 3202
Location: lancashire

2006 Porsche 911

PostPosted: Sat Jul 08, 2017 9:56 pm    Post subject: Reply with quote

The mount on mine snapped as well..Again I heard a ping that sounded like a coil spring snapping!!!
The only clue was the exhaust tail pipe at a weird angle..
Again welded in situ and now all good..
I love my 986..The best Porsche model ever... and I've owned a few
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2960
Location: North East England


PostPosted: Sun Jul 09, 2017 5:26 pm    Post subject: Reply with quote

Totally agree with you Kas750. I've owned a few too now and the lowly old 986 is every inch a true Porsche.

Just to finish this bit off, here's a pic of the gearbox completely fixed..

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Demort
Paul Ricard


Joined: 21 Mar 2015
Posts: 3107
Location: Sussex


PostPosted: Sun Jul 09, 2017 5:47 pm    Post subject: Reply with quote

Surprised

2 of you have had this and ive never even seen it !

Excellent idear for a repair though .. ill remember it for when i do come across this Thumb
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2960
Location: North East England


PostPosted: Sun Aug 20, 2017 2:48 pm    Post subject: Reply with quote

I was trailbraking into a left hander 2 days ago when I heard a 'clink' and a thud. As I was late for work I carried on cautiously but noticed that the car was pulling to the left and there was a horrible noise like the front wheel rubbing under heavy braking.

Today is the first time I've been able to get the car on the lift and have a look:

Broken tuning fork:


Slipped coffin arm bush insert:


Drop link broken:


As you can see, there's an awful lot of damage happened due to the failure of the tuning fork. As you can see from the following pictures it is clear that the polybush didn't allow any 'give' next to its anchor point which led to it fatiguing and then failing:




Without the tuning fork keeping the centre of the wheel pinned in position, under heavy braking the wheel was moving back and rubbing on the leading edge of the front wing. The only think really keeping the hub where it should be was the coffin arm but this was clearly overly stressed in order for the bush insert to move out of the arm.

Needless to say I won't be buying polybushed tuning fork arms again. Good old OE bog standard replacements from now on. I'm obviously going to replace the pair even though only one is damaged along with a new coffin arm.

Could have ended in tears....

nooo
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Demort
Paul Ricard


Joined: 21 Mar 2015
Posts: 3107
Location: Sussex


PostPosted: Sun Aug 20, 2017 3:19 pm    Post subject: Reply with quote

You where very lucky there as thats a pretty bad component to have fail .. interesting what the cause of it is though .
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Marky911
Imola


Joined: 04 Jun 2009
Posts: 850



PostPosted: Sun Aug 20, 2017 5:08 pm    Post subject: Reply with quote

Top work Raggy, as ever. Especially the suspension refresh though. Cool

What a freak failure on that tuning fork. As Demort says, lucky escape there.
 
  
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