Dr.AK
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Jul 26, 2019 20:49:02 GMT
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Thanks! Yeah, I'm quite lucky with the place. It was a lucky find when I had to move out of my old unit. It was built in the 50ies without a permit, intended as a basement for a house. Due to it being built with a permit, city shut it down and only the basement ever got built and was outfitted to use it as a garage. Some guy used it as a sales shop for a few years and removed the garage doors and fitted some windows in place. I've got literally the greatest landlord ever for this thing as he basically just told me "What do you want to do in here? Wrench on cars eh? Yeah, I'll have my workers install some new garage doors and redo the roof." and actually went through with it. I did the other renovation work myself but his construction crew also knocked down the wall for me so I could drive a car into the back. The front fits two cars and from the outside looks just like a normal double garage. Behind that is a 100m² / 1076sqft room which I use for actually working on my cars and such. The height is sadly not enough for a full lift, but I'm thinking of installing a medium height scissor lift next year... ![](https://i.imgur.com/F1Zoavk.png) When I first went to look at the place about 2 years ago: ![](https://i.imgur.com/HP4H3fA.png) ![](https://i.imgur.com/vnwg7Vl.png) Work work work ![](https://i.imgur.com/uEtcMSe.png) ![](https://i.imgur.com/tWaijRK.png) ![](https://i.imgur.com/2GeWvp5.png) this radio is amazing. which model is it? It's a Blaupunkt Paris RCM104. There's a few others that look nearly identical with the same model code (RCM104) but a different city in the Name (I know there's the Models Frankfurt, Stockholm and Barcelona also). They all just differ in the specs / options a bit. These radios are from the mid 90ies, so a bit of luck is involved in finding one in good working condition.
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Dr.AK
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Posts: 426
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Sept 13, 2019 18:25:51 GMT
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Dr.AK
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Long time no update! A few weeks onward from my last post, I managed to source a matching throttle position sensor. Porsche wanted 400€ for a new one. A new Bosch one would've been about 200€, but they were out of stock everywhere. After a bit of research I found out that the TPS from a Audi 100 is exactly the same one I needed and found one through Audio Tradition for 60€. It's a Bosch piece as well... ![](https://i.imgur.com/UtGfjwl.png) When I tried to install it, I learned about the wonders of the 944 S. All 944 models have the throttle body at the front of the engine. Only the 944 S with the 2.5 16 valve has got it at the back between the engine and the firewall. To remove it, you need to remove the intake manifold as well. I figured when I'd remove that, I'd also replace all the rubber hoses and the Idle Control Valve and a few gaskets and cleaned the throttle body while I was at it. The idle control valve was a similar story to the throttle position switch. Porsche wants 400, a Bosch one would've been 200 but out of stock everywhere. Finally managed to find one from a little known aftermarket company called 'Löwe'. Made in china, but a few 944 guys in Germany have had good experiences with these parts and it was only like 60€. Life got in the way and the car sat until this April when I could finally start to work on it. ![](https://i.imgur.com/fcRvbDPh.jpg) ![](https://i.imgur.com/9NfaEssh.jpg) ![](https://i.imgur.com/cR8kgEBh.jpg) ![](https://i.imgur.com/JxQJb7gh.jpg) Finally got to drive it again! ![](https://i.imgur.com/LgaMPGX.png) ![](https://i.imgur.com/zVDWwGU.png) But the clutch was about dead. It was nearly dead when I got the car, but it was finally time to replace it. A major job, with the transmission in the rear and the clutch in the front, connected by a torque tube. Luckily I had my father to help me - he was a mechanic by trade 30 years ago before he switched professions and still knows a lot about car mechanicals and he's who taught me all I know about wrenching. ![](https://i.imgur.com/TJch7aN.png) First the exhaust needs to come off: ![](https://i.imgur.com/EbWuvqa.png) Disconnecting of two sensors that need to come out for the clutch housing to be removed... ![](https://i.imgur.com/OeD1bNN.png) Next we disconnected the drive shafts ![](https://i.imgur.com/Znglp9G.png) And some time later, with a lot of cussing and cursing, the transmission was finally out ![](https://i.imgur.com/p1SKH6A.png) A view under the car now, where you can see the bell housing at the end of the torque tube: ![](https://i.imgur.com/gFck62G.png) The torque tube has to be moved towards the back of the car to make enough room in the front to get the clutch out. To do this, you need to turn the whole tube clockwise and then push it towards the rear. A bit tricky if you don't know what you're doing like we did... but we managed in the end! With the tube slid out of the clutch: ![](https://i.imgur.com/3KEGoD3.png) Clutch housing off, finally starting to get to the core of things! ![](https://i.imgur.com/kkmylWO.png) The old clutch was dead. Porsche fitted a clutch with a rubber part to potentially soften gear changes. This rubber block was completely ripped off, so the clutch was basically 'flopping around' when you changed gears. You can imagine how THAT felt. ![](https://i.imgur.com/kE0AlES.png) ![](https://i.imgur.com/COfluu8.png) What all had to be removed to get to this point: ![](https://i.imgur.com/ooaVWsAh.jpg) ![](https://i.imgur.com/RvGX1hch.jpg) While I had the clutch off, I also changed the pilot bearing (in which the torque tube runs) and the crankshaft oil seal. To get the oil seal in, I 3d printed a tool to hammer it in... it did not survive. But the seal is sitting perfectly. ![](https://i.imgur.com/EJFMONeh.png) ![](https://i.imgur.com/ruqjtJSh.jpg) Slowly getting things back together. ![](https://i.imgur.com/ff0xjOwh.jpg) Torque tube mounted up ![](https://i.imgur.com/xWi7gEeh.jpg) Starter mounted ![](https://i.imgur.com/iv66UE7h.jpg) Then I got around to cleaning the transmission. ![](https://i.imgur.com/sbzMxRch.jpg) And drained the oil and filled it up with fresh transaxle oil. ![](https://i.imgur.com/t9jeCfoh.jpg) Ready to re-install the transmission ![](https://i.imgur.com/zI0sunDh.jpg) Aaaaand it's in. ![](https://i.imgur.com/CFeuB1Eh.jpg) First test drive was a success, everything worked flawlessly and the new clutch completely transformed the car. ![](https://i.imgur.com/W29aBa8h.jpg) Then I finally got to enjoy the car for a short while and took some pretty photos ![](https://i.imgur.com/qEZW66Hh.jpg) ![](https://i.imgur.com/XgWdKSlh.jpg) ![](https://i.imgur.com/uVswZJeh.jpg) ![](https://i.imgur.com/PfryrGih.jpg) ![](https://i.imgur.com/553nBMWh.png) ![](https://i.imgur.com/4QKroWmh.jpg) ![](https://i.imgur.com/LxsvDOzh.jpg) ![](https://i.imgur.com/v2vAchuh.jpg) ![](https://i.imgur.com/QE86hcXh.jpg) ![](https://i.imgur.com/x4JbWl3h.jpg) ![](https://i.imgur.com/aqj94vhh.jpg) ![](https://i.imgur.com/LY0CBGGh.jpg) ![](https://i.imgur.com/WEW1SC8h.jpg) ![](https://i.imgur.com/Q1Tvq2th.jpg) ![](https://i.imgur.com/ZaEOU5jh.jpg) ![](https://i.imgur.com/2E0vPFqh.png) ![](https://i.imgur.com/J1gKsphh.png) ![](https://i.imgur.com/sN4vhLEh.png) The car decided to give me some more headaches though, as the generator died. I'm currently waiting on a new one.
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shin2chin
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Making curse word cars slightly better
Posts: 820
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Jun 17, 2020 16:04:57 GMT
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You can definitely save some cash by searching around for equivalent parts. My 924 has loads of VW and Audi bits which were significantly cheaper than the same from Porsche.
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1977 PORSCHE 2.0na 924 1974 VW Beetle 1600
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Jun 17, 2020 16:35:18 GMT
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Wow, just love the way this thing looks- nice job. Now that the clutch is done, I'm sure it's a hell of a lot of fun to drive too!
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1985 Volvo 760 "Jurbo"
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Dr.AK
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Jun 29, 2020 13:07:18 GMT
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You can definitely save some cash by searching around for equivalent parts. My 924 has loads of VW and Audi bits which were significantly cheaper than the same from Porsche. Yup, it's just a shame the more developed the 944 got, the less shared parts it used. Like your 924 has basically an Audi engine. The one in the 944 is basically a 928 V8 cut in half. Mine's even more special as it's the 2.5 16 valve, which has a bunch of specific parts that are hard to find now. I've seen used intake manifolds go for 2 grand, for example. Even suspension wise - things like the early cars using Golf 1 control arms in the front no longer apply to mine as it's got the wider axles which have their own aluminum control arms. Oh well, it could be worse. Wow, just love the way this thing looks- nice job. Now that the clutch is done, I'm sure it's a hell of a lot of fun to drive too! Thanks! Yeah, it was fun for a few weeks, but now the generator is dead. I've removed it and sent it in to be overhauled , but it's not back yet. Hopefully it arrives soon, so I can back to zipping around in this thing!
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You can definitely save some cash by searching around for equivalent parts. My 924 has loads of VW and Audi bits which were significantly cheaper than the same from Porsche. Had a dodgy temperature sender on mine, (no not the one that just controls the gauge, the one that tells the ECU what's going on, or not in my case) that would intermittently shut the engine down. Phoned up my local European car guy here, more out of optimism than expectation, and within the day had a replacement sender, a BMW part, for pennies. Result! Dr.AK does the new clutch have all that rubber as well?
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Last Edit: Jun 30, 2020 4:53:55 GMT by georgeb
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Dr.AK
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Nope, the new one is a conventional one made by Sachs! I do believe even if you order the clutch new from Porsche they no longer carry the rubber one but you'll instead get a conventional Sachs one in a Porsche packaging.
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Dr.AK
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I always liked the 7 slots, the same or very similar design as the 928's. Go for it!
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Still learning...still spending...still breaking things!
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I broke one of these (as far as i can assertain, virtually identical model, 944s 16v) up a couple of years back (actually belonged to a coleague but was terminally rusty) but his had slightly a slightly different front valence, and an additional rear splitter, all of which i understand were original to the car. I know he ran 16" teledials on the back, and 15" on the front which apparently optimised the handling..... I don't pretend to know if thats correct, but in the day he was quite involved in it, so he obviously changed them for a reason!!
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Current fleet: '58 A35 (half mine) '67 11 window splitscreen vw (half mine) '77 mini 1000 (not quite 1000 any more!!) '86 Armstrong MT500 '89 XR4X4 '94 Corrado VR6 Some sort of sevenesque kit car (no age yet!!) '01 Mondeo estate 2.0 (engine eventually destined for kit car!) - scrapped, engine only left! '98 E300 estate, rusty but seemingly reliable, fast-ish tat hauler. eventual engine donor A35 van, or whats left of it after it lived in a field for many years
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Dr.AK
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I broke one of these (as far as i can assertain, virtually identical model, 944s 16v) up a couple of years back (actually belonged to a coleague but was terminally rusty) but his had slightly a slightly different front valence, and an additional rear splitter, all of which i understand were original to the car. I know he ran 16" teledials on the back, and 15" on the front which apparently optimised the handling..... I don't pretend to know if thats correct, but in the day he was quite involved in it, so he obviously changed them for a reason!! Sounds like it was a S2 which has a few differences. Mostly the different front valence and the rear splitter, but also the engine was increased from 2,5l to 3,0l. Was the biggest inline four in a production car at the time! Anyways, the car has been sitting in the garage for the past few weeks as it refused to charge the battery properly. I swapped out the generator regulator, still the same. So I went and looked for a new regulator. Oh boy. New from Porsche it's 899€. An aftermarket one is 350€. I found a specialist who sells refurbed OEM parts for 250€ and got him to just overhaul mine. I know it wouldn't have made a difference wether I had mine overhauled or chose another one in exchange, but I felt that with an overhaul of the original generator it would at least stay true to the car, be the part that belonged with the car. That took some time to arrive, but it finally showed up today. ![](https://i.imgur.com/0MR82dVh.jpg) ![](https://i.imgur.com/KbHN6Psh.jpg) So I went over to the garage and installed it straight away. Went and started the car... and it looked good at first, if a bit weak. I measured 13,2V at the battery. Did a test drive and had my eye on the volt meter in the dash. At first it stayed at 13V, then it fell to 12V, rose again, fell again and so on. Something's not right. Back into the garage. My father was with me in the garage but even together we couldn't find the fault. Our last idea was to measure the voltage directly at the cables from the generator, so I was going to start the car, he would pull the cables from the battery and measure there. But just as I started the car he shouted 'Stop! There's sparks!' from where he was standing next to the open engine bay. After some digging, we found the culprit. Looks like we didn't properly tighten the ground cable that has to be removed for the clutch change and the nut rattled loose and got lost on the way. The cable was hanging loosely on the bolt and thus sometimes it had a ground connection, sometimes it didn't. Found a new nut and fastened it up again and voila, everything works now. Steady voltage of 13,8V when the car is idling, it stay steady during driving as well. Looks like I didn't have to change the generator at all, but oh well. It doesn't hurt and in fact only makes the car better so it was still worth it. ![](https://i.imgur.com/DetsMdjh.jpg)
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Dr.AK
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Jul 10, 2020 23:07:38 GMT
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Jul 10, 2020 23:59:59 GMT
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AK, your photography is seriously excellent. The clutch-job is listed in estimating guides at 17-20 hours... a pig of a job, as is the replacement of the heater core. I saved an 87 924S from the scrapman and am documenting its rebuild on Pelican, here: forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.htmlYou will see much that is familiar ... I even took my torque-tube apart to replace the ball bearings. This car was last in use 12-13 years ago and I **think** what caused it to be parked badk then was the rubber-centered clutch exploding. Anyone interested, please visit. John
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Man you have a hell of an eye- those photos are fantastic. Sorry to hear about the unnecessary generator swap, but as you said it definitely won't hurt to have refreshed it.
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1985 Volvo 760 "Jurbo"
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Dr.AK
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Jul 26, 2020 13:43:55 GMT
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Thanks guys, always nice to hear my photography is appreciated! Apart from cars it's my other big passion in life. Yesterday was a good day. First, I met up with some fellow transaxle owners on a rest stop at the Autobahn A44. Three 944 8v N/As, a 924 and a 924S, well and my 944S obviously. ![](https://i.imgur.com/r0JKjEdh.png) Then we drove on and crossed the border to Belgium. At Lac de la Gileppe we met up with some others with a MGB GT and a 356 SC. They had prepared a nice route for us, a wild roller coaster through the Ardennes and specifically the countryside surrounding Spa-Francorchamps. The roads were quite empty so we were free to enjoy the curves. Belgium has some really nice driving roads for sure, although the surface on some of them is a bit questionable. ![](https://i.imgur.com/AH9xIYEh.jpg) ![](https://i.imgur.com/5XD07DAh.png) ![](https://i.imgur.com/MVtHb2eh.png) We stopped for fuel first thing after we headed out. Transaxle takeover at the tiny Total station in Jalhay. :cool: ![](https://i.imgur.com/L6YkpdHh.png) Then we went on the first leg of the cruise and ended up at the gates to Spa. The gates were closed but we could hear some cars blasting around. ![](https://i.imgur.com/eaj9WY7h.png) ![](https://i.imgur.com/MTAQlImh.jpg) ![](https://i.imgur.com/sAUZxlhh.png) Headed out again and stopped at a different section of Spa from where we could see some of the track through the fences. Sadly they were all closed due to the current situation, but we at least got a glimpse of what was going on. Some kind of Porsche Experience thing with a lot of extreme track prepped 911s blasting round the track. Sadly I wasn't able to grab any pictures. ![](https://i.imgur.com/fzGeajmh.png) ![](https://i.imgur.com/JY6AsIwh.png) Headed out again after a while. ![](https://i.imgur.com/R8eeOOJh.jpg) ![](https://i.imgur.com/o1YegCih.jpg) Next stop, Le Herou for a picnic. ![](https://i.imgur.com/2yyOLvJh.jpg) ![](https://i.imgur.com/260vhF1h.jpg) ![](https://i.imgur.com/XdqpEOqh.jpg) ![](https://i.imgur.com/PzEete9h.png) ![](https://i.imgur.com/zhIntE2h.png) Next up, we headed to Luxembourg to fill up again, as fuel is quite cheap there for our European standards. I filled up on some 95 octane for 1.08€ per liter - that's about 4,77$ per gallon. Cue another gas station takeover. ![](https://i.imgur.com/ZtoCcsFh.jpg) ![](https://i.imgur.com/eCLTwoXh.jpg) ![](https://i.imgur.com/TZZksush.jpg) ![](https://i.imgur.com/vLPd5t8h.jpg) ![](https://i.imgur.com/XYPNIVxh.png) ![](https://i.imgur.com/TOBDiLyh.jpg) ![](https://i.imgur.com/sCGkWVnh.jpg) Headed back out onto the road, back into Belgium and back in the direction of Spa. On the way, another quick break at the viewpoint 'Zum Buren'. ![](https://i.imgur.com/vqO6KPsh.jpg) ![](https://i.imgur.com/EKnbULnh.jpg) ![](https://i.imgur.com/NEzbJxxh.jpg) ![](https://i.imgur.com/5fvkaYdh.jpg) ![](https://i.imgur.com/b6ajSMXh.jpg) ![](https://i.imgur.com/IRNEKa5h.jpg) ![](https://i.imgur.com/MgeFIh5h.jpg) Then back to Spa, where we took some pictures on a left over part of the track from the 50s. ![](https://i.imgur.com/JAT7P17h.jpg) ![](https://i.imgur.com/3I5CiRlh.jpg) ![](https://i.imgur.com/CSHdAz2h.jpg) ![](https://i.imgur.com/AIHDWw5h.jpg) ![](https://i.imgur.com/KrcA28Uh.jpg) After that, we all headed back home. All in, I drove about 500kms yesterday and the 944S ran without trouble. In fact, the more I pushed the car, the happier it was. The car just wants to run and run and run. And it absolutely flies through corners. It's absolutely amazing. It's not a very powerful car but as long as you keep the revs up, it's one of the most capable affordable cars for curvy roads that I can imagine. None of the others had any problems as well and we all had a blast, so I'd count it as a very successful day in these troubled times in 2020. :cool:
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ZXRob
Europe
Posts: 1,193
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Really nice car man I will keep an eye out for it when I am out and about.
The event at Spa was the Porsche GT track day from Manthey Racing.
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Dr.AK
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Ohhhh, that explain it then! As we were taking the last pictures on the old part of the track (which nowadays is a public road), a VW T6 with 'Manthey Racing' on it's side came flying past, honking it's horn and all of the people inside were waving ![:D](//storage.proboards.com/forum/images/smiley/grin.png)
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Jul 27, 2020 12:29:58 GMT
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The MG BGT is, in terms of purpos and configuration, an ancestor of the 924/44/68: useful sports car with hatch.
Great thread, I always enjoy it.
John
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Dr.AK
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Thanks! Yeah, that's my take on the MGB GT as well. It's a spiritual ancestor. I admit that I did not really have these cars on my radar before, but spending some time with one has changed that. Lovely motors. Changed the fuel filter today. Had it sitting around for a while but haven't gotten around to it. Surprised by how much of an effect it had on the car. The car pulls noticeably better and smoother from the low end now. Now the only thing really annoying me is the engine mounts, but at the moment I'm not willing to shell out the 400€ for the OEM Porsche ones and the after market ones are reportedly a waste of money. A project for the winter. ![](https://i.imgur.com/UKYp05Uh.jpg) ![](https://i.imgur.com/Py9qmDHh.jpg) I'm also slowly hanging up more and more stuff on my garage walls. ![:D](//storage.proboards.com/forum/images/smiley/grin.png) Today I added two posters from two Porsche events I attended last year and the 1985 Porsche line-up! The wall in front of the car houses a photo of some of my friends including one who sadly is no longer with us, two photos I took and printed (one of my old E36, the other a roller of a friends old R32 Skyline) and the rest is all vintage ads from car magazines from the 80s and 90s.
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