Caledonian Posted 26July, 2014 Author Report Share Posted 26July, 2014 The only problem with " I'll do that while i'm in there" jobs is that they tends to be a lot of cleaning and painting involved, which is not only is messy its also time consuming. Managed to squeeze in an hour last night to take the other driveshaft off and get the oil tank out to clean and paint. To avoid getting any rubbish in the tank while cleaning i needed to cover off all the holes, could thing how i was going to do the oil filter fitting.... then became it was obvious! Use the old oil filter.... For some reason there seems to be an abundance of elastic bands in our house right now, but they came in quite handy. After a can of degreaser and some vigorous brushing many years of grime was removed. The tank is in excellent condition with no damage or corrosion anywhere. The oil level sender seal must be weeping a bit going by the concentration of grime here... I'll be soaking these with some penetrating oil before trying to remove the nuts, don't want a broken stud here. Link to comment Share on other sites More sharing options...
Caledonian Posted 26July, 2014 Author Report Share Posted 26July, 2014 Not boring at all. I think some of us voyeurs would like to know how much the final pain is, and what the improvements are when it's all done. Funny enough, the car ran really well and the oil leak was just an annoyance really. As she was due for a service I thought I'd just do everything at once, then of course I thought my leak was only going to be seals not a cooler and the driveshafts were a surprise. Cost wise, the parts bill and some specialist work is looking to be close to $1000, at this stage anyway but it might be more if i find anything else. Once its back together I'm not expecting anything mind blowing performance wise, but I will have some peace of mind and more confidence in it reliability. Link to comment Share on other sites More sharing options...
Quozl Posted 26July, 2014 Report Share Posted 26July, 2014 Mate huge respect to you, I wish I had the knowledge and skills to save the dollars you have here by doing the work yourself, It's been great following your journey. In my case I just have to save up each time until I can afford to get someone to do the next stage I need doing but it's great watching someone with the confidence and skills to do it themselves. Looking forward to seeing you button it all up at the end. Cheers Al Link to comment Share on other sites More sharing options...
Caledonian Posted 27July, 2014 Author Report Share Posted 27July, 2014 Mate huge respect to you, I wish I had the knowledge and skills to save the dollars you have here by doing the work yourself, It's been great following your journey. In my case I just have to save up each time until I can afford to get someone to do the next stage I need doing but it's great watching someone with the confidence and skills to do it themselves. Looking forward to seeing you button it all up at the end. Cheers Al Thanks for the kind words Al, although what I'm currently doing to my car is mainly maintenance work. There are others on here who have taken on much more technically challenging tasks than me. I could say I work on the car myself as it's my passion for the Porsche marque, that drives me to pull each component apart, so I can connect with it and understand it needs and wants. However, in reality it's the same has most people, mortgage, kids and general lack of cash Joking aside, i do really get a lot of satisfaction for doing the work myself, even the cleaning bit. More installments to come.... Link to comment Share on other sites More sharing options...
Caledonian Posted 27July, 2014 Author Report Share Posted 27July, 2014 Got some more cleaning done ready fro the re install, probably spent too much time on the engine bay that you don't see when the car is back together, but its therapeutic. The axle hub flanges were first on the list and thanks to bargain purchase of 2 rolls of hand towel for $2! I did't have to start ripping up old t-shirts for rags. I scooped out most of the old grease with the paper towel and then just blasted it with the cheap cans of degreaser from S/cheap While not clinically clean it's good enough. Remnants of the old gasket between the CV joint and flange: Continued on next post: Link to comment Share on other sites More sharing options...
Caledonian Posted 27July, 2014 Author Report Share Posted 27July, 2014 I had noticed when i was removing the drive shafts that one of them had different sized bolts, and there was no lock plates (or moon washers) as they are also known. After looking into it some more, it turns out 3 of the joints had 45mm bolts and only 1 had 50mm? 50mm should be the correct length, or i thought it was. I popped the CV joint I had previously cleaned for inspection on to the gearbox flange for comparison: 50mm on top 45mm lower 50mm nipped up on the gearbox flange for comparison, about 3 1/2 threads showing but no lock plate (in photo you only see 2 1/2 threads) 45mm nipped up on the gearbox flange for comparison, just see the tip of the bolt showing through. Spring washers (left) and the correct Schnorr washer (right) I was going to get new Schorr washers and I believe they are relatively available from most good nut & bolt suppliers, I will need new bolts too. As for the lock/moon washers, well there are plenty of threads about this. So I'll try not to go into too much detail about whether they are required or not. I had noticed when i was removing the drive shafts that one of them had different sized bolts, and there was no lock plates (or moon washers) as they are also known. After looking into it some more, it turns out 3 of the joints had 45mm bolts and only 1 had 50mm? 50mm should be the correct length, or i thought it was. There appears to be no real debate in regards to using Schorr or equivalent type washers, the debate starts around the need for the plate to ensure adequate clamping of the CV joint to the flange. So the bolts don't work loose the Schorr washers need to be against a hard surface, and the general opionion is that the softer metal on the CV joint boot flange is not suitable and that can be why some CV joints can work loose. The lock washers are around $10ea so thats $120 a set, I'm sure there will be a less costly alternative, VW perhaps? Link to comment Share on other sites More sharing options...
Mike D'Silva Posted 27July, 2014 Report Share Posted 27July, 2014 $10 for a single washer? Link to comment Share on other sites More sharing options...
Russ Posted 27July, 2014 Report Share Posted 27July, 2014 loctite the threads in, use the spring washers? and even then use a steel washer behind it if you're worried about soft alloy in the boot surround? IIRC VW's have a plate washer that fits between 2 bolts across the face of the steel surround to the boot EDIT: like this: I don't know if i'd be too worried about them coming loose with all the above precautions, and if so make it something you check when you do an oil change. Link to comment Share on other sites More sharing options...
Caledonian Posted 27July, 2014 Author Report Share Posted 27July, 2014 I was of the same opinion initially Russ, then i started reading about all the failures.. might get a T&D opinion to see what they do. Link to comment Share on other sites More sharing options...
Zelrik911 Posted 27July, 2014 Report Share Posted 27July, 2014 Great thread, I am learning lots from your Tips, as I may have to do this soon myself.. I have a Query - back in an earlier post you mentioned getting some: Gearbox mount curved washers - missing x2 (should be 4) I recently replaced my g/box mounts & only found 2 curved washers underneath, Do you mean that there are meant to be an extra 2 washers on top of the rubber mount (between the mount & the body)? Regards Peter 3.0L SC in Melb. Link to comment Share on other sites More sharing options...
Caledonian Posted 27July, 2014 Author Report Share Posted 27July, 2014 Great thread, I am learning lots from your Tips, as I may have to do this soon myself.. I have a Query - back in an earlier post you mentioned getting some: Gearbox mount curved washers - missing x2 (should be 4) I recently replaced my g/box mounts & only found 2 curved washers underneath, Do you mean that there are meant to be an extra 2 washers on top of the rubber mount (between the mount & the body)? Regards Peter 3.0L SC in Melb. If this is correct, yes. Item 6 Qty 4 Link to comment Share on other sites More sharing options...
Caledonian Posted 27July, 2014 Author Report Share Posted 27July, 2014 I know these before and after shots are popular so here is the gearbox tunnel area: Before After: Link to comment Share on other sites More sharing options...
FlatSix Posted 27July, 2014 Report Share Posted 27July, 2014 I can't see my reflection in it yet, keep cleaning! Do you think you will have it all back on by coffee and cars? Link to comment Share on other sites More sharing options...
Russ Posted 27July, 2014 Report Share Posted 27July, 2014 let us know what Ted says, I'm keen to hear too (they did one of my boots for roadworthy when I first got the car) everyone cleaning up their engine bay makes me want to do mine. but not enough to actually pull the engine out and find things wrong. I think that's the issue with 'while i'm there' jobs, where to stop! Link to comment Share on other sites More sharing options...
CarreraG50 Posted 27July, 2014 Report Share Posted 27July, 2014 Mike, if your worried about your CV bolts coming loose (mine did on the 914, had to flat bed it home ). (actually a couple came loose then the two remaining couldn't handle the torque of the big block 1.8 and snapped) The fix i came up with was to drill small holes through the head and then wire them together in pairs. Having said that, haven't done it on the 911 Link to comment Share on other sites More sharing options...
Russ Posted 28July, 2014 Report Share Posted 28July, 2014 yeah, safety wiring them is talked about in a pelican thread I found. I'd feel better having not known this is a problem though Link to comment Share on other sites More sharing options...
Caledonian Posted 28July, 2014 Author Report Share Posted 28July, 2014 I can't see my reflection in it yet, keep cleaning! Do you think you will have it all back on by coffee and cars? Probably not with the car as the parts won't be here in time, will try to make it down for a look and check out your rim (s) Link to comment Share on other sites More sharing options...
FlatSix Posted 28July, 2014 Report Share Posted 28July, 2014 Do you want me to bring my AP cleaner? Link to comment Share on other sites More sharing options...
Caledonian Posted 28July, 2014 Author Report Share Posted 28July, 2014 Do you want me to bring my AP cleaner? Yes please but I'm not 100% sure I'll get there yet.... Link to comment Share on other sites More sharing options...
SteveT Posted 28July, 2014 Report Share Posted 28July, 2014 I could pick it up for delivery to Keperra? Or drop it off at your place if you don't have any wheels at all. Link to comment Share on other sites More sharing options...
Caledonian Posted 29July, 2014 Author Report Share Posted 29July, 2014 I could pick it up for delivery to Keperra? Or drop it off at your place if you don't have any wheels at all. Might take you up on that Steve, should know later in the week whats happening..... Link to comment Share on other sites More sharing options...
Caledonian Posted 29July, 2014 Author Report Share Posted 29July, 2014 $10 for a single washer? Well I suppose has each washer has 2 holes it could be seen as $5 a washer..... Link to comment Share on other sites More sharing options...
twood Posted 29July, 2014 Report Share Posted 29July, 2014 You had me at "you are welcome to them" If you don't mind Ken yes, mine will go back on but are a bit tired but if your old ones are better I'll defiantly take them off your hands... I did have new pair on the parts list, but apparently we have to feed the kids every day! so something had to go. BTW your thing is ordered but I just got an e-mail saying 2 of the parts i ordered are out of stock, so they have not shipped the order until i say if i want to wait of go without. I asked how long before they were in stock, so just waiting for a reply. Mike I have the heater tubes from my rebuild but they may be worse than your tubes. I will throw them into my car Saturday morning - will you be there? If you can use them good otherwise will probably toss them Link to comment Share on other sites More sharing options...
Caledonian Posted 30July, 2014 Author Report Share Posted 30July, 2014 Trying to be there Ken, mine are usable but tatty but will have look at your one anyway. Link to comment Share on other sites More sharing options...
Caledonian Posted 30July, 2014 Author Report Share Posted 30July, 2014 let us know what Ted says, I'm keen to hear too (they did one of my boots for roadworthy when I first got the car) everyone cleaning up their engine bay makes me want to do mine. but not enough to actually pull the engine out and find things wrong. I think that's the issue with 'while i'm there' jobs, where to stop! Ok, spoke with Steve at T&D and Bob Wyns also to see if they had any. One said, use them if there bit don't need them other said not fitted on my model? The early Tips (fancy for Sportomatic) have a different CV with 4 x M10 bolts, but should have the moon washers, apparently. So no further forward really, just more versions of the truth:) Link to comment Share on other sites More sharing options...
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