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michaelodonnell123
Joined: 20 Mar 2015
Posts: 235
Location: New Jersey
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 Posted: Wed Jul 27, 2016 1:51 pm Post subject: |
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This is my opinion of bringing an old 924 back to life. Do not 'CHECK' the timing belt, instead you should just 'CHANGE' the timing belt. Then try to get the engine going. Once you get it going then be prepared to possibly need to change out all the hoses, water pump, master/slave cylinder, all fluids & filters, fix exhaust leaks, change the shocks & springs. Also pull the gas tank and change the fuel hoses there as well. And finally put new rotors ,pads and tires all around. Then you will have a roadworthy car. I estimate that you will need to spend around 4K to get it into top shape.
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1988 Porsche 924S
2007 Jaguar XK
2012 Fiat 500 |
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jvandyke
Joined: 30 Mar 2016
Posts: 212
Location: Hudsonville, MI
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| Posted: Thu Jul 28, 2016 7:07 am Post subject: |
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can't get the shaft/ujoint out of rack, Clark's says punch and hammer? I took the pinch bolt out, even tapped a large screw driver in the slot as a wedge to help but it doesn't want to separate. Is there something else to take off first? The top of the shaft that goes up into the u-joint seems to have a knurled nut on it but I just can't tell if it's supposed to come off or what.
here's an attempt at a picture (photobucket is dead AGAIN!)
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87 924S project, '83 944 engine,
my son's first car. |
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jvandyke
Joined: 30 Mar 2016
Posts: 212
Location: Hudsonville, MI
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| Posted: Thu Jul 28, 2016 7:09 am Post subject: |
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| michaelodonnell123 wrote: | | This is my opinion of bringing an old 924 back to life. Do not 'CHECK' the timing belt, instead you should just 'CHANGE' the timing belt. Then try to get the engine going. Once you get it going then be prepared to possibly need to change out all the hoses, water pump, master/slave cylinder, all fluids & filters, fix exhaust leaks, change the shocks & springs. Also pull the gas tank and change the fuel hoses there as well. And finally put new rotors ,pads and tires all around. Then you will have a roadworthy car. I estimate that you will need to spend around 4K to get it into top shape. |
Yes, we were well down that road although timing belt was just checked, not changed since if engine is crap, I don't want a $500 timing belt kit staring at me. It won't cost that much. We're doing all the work ourselves. Parts are expensive, but not THAT expensive!
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87 924S project, '83 944 engine,
my son's first car. |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11723
Location: PacNW
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| Posted: Thu Jul 28, 2016 7:53 am Post subject: |
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Soak that u joint in a 50/50 solution of ATF and acetone.
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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hdrider19
Joined: 03 May 2016
Posts: 193
Location: Catawissa Missouri(40 mi sw of St Louis)
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| Posted: Thu Jul 28, 2016 8:47 am Post subject: |
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There is a pinch bolt at the upper u-joint. You might try removing it too. Might let it slide up enough to get off rack spline.
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87 924S |
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jvandyke
Joined: 30 Mar 2016
Posts: 212
Location: Hudsonville, MI
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| Posted: Thu Jul 28, 2016 11:53 am Post subject: |
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After too much time on it we just dropped the crossmember and let it's own weight help. Still had to ram a wedge in the gap, then a full size crow bar, finally I used a pickle fork/ball joint separator and a small sledge hammer and it finally gave it up.
We have the engine out now and are cleaning it up.
I'm anxious to pull the bell housing and see the release bearing (the notched washer was breaking and throwing pieces of itself out the starter opening).
Long day.
Cleaning engine bay and pulling wiring out and see what's what.
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87 924S project, '83 944 engine,
my son's first car. |
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hdrider19
Joined: 03 May 2016
Posts: 193
Location: Catawissa Missouri(40 mi sw of St Louis)
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| Posted: Thu Jul 28, 2016 1:16 pm Post subject: |
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Have you determined what started the fire? I have my engine out and apart right now. Just want to make sure this doesn't happen to mine too.
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87 924S |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11723
Location: PacNW
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| Posted: Thu Jul 28, 2016 3:50 pm Post subject: |
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HRider, call Rennbay for a fuel line repair kit. Much easier to install with the engine out.
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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edredas
Joined: 09 Dec 2004
Posts: 861
Location: Charlotte, NC
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| Posted: Thu Jul 28, 2016 4:49 pm Post subject: |
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| jvandyke wrote: | | After too much time on it we just dropped the crossmember and let it's own weight help. Still had to ram a wedge in the gap, then a full size crow bar, finally I used a pickle fork/ball joint separator and a small sledge hammer and it finally gave it up. |
That steering shaft is a bear sometimes, glad to hear you got the engine out!
| hdrider19 wrote: | | Have you determined what started the fire? I have my engine out and apart right now. Just want to make sure this doesn't happen to mine too. |
I don't want to hijack his thread, but these cars need special attention. These cars burn easily, you have been warned! Replace all the hoses, and spark plug wires. Faulty spark plug wires can arc on the fuel rail so toss them! Also, after having the fuel system open for any reason always have a friend start the car while you look for any fuel leaks. If you finish the car at night do not start it until the next day. You must have the car out in broad daylight! I tore a seal on my rear injector and it was spewing fuel and I had no idea because it was dark in the shop! I got lucky, perhaps you won't! Have a fire extinguisher ready and have your friend shut the car off immediately if you see anything!
I hope that helps!
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'84 944 -White, Brown interior
'84 944 -Red, Automatic
'86 944 -Garnet, Fully loaded, Koni suspension
'87 924S -Red, 300hp 951 swap
'87 924S -Red, Project Car
'88 924S -Red, Daily Driver |
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jvandyke
Joined: 30 Mar 2016
Posts: 212
Location: Hudsonville, MI
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| Posted: Thu Jul 28, 2016 10:14 pm Post subject: |
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yep, what he said, 
While removing bits yesterday I noticed the right engine mount had no shield, I believe there is supposed to be one, that mount was collapsed, I'd like to refit the shield in an attempt to get more life out of the next mount, anyone have one?
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87 924S project, '83 944 engine,
my son's first car. |
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hdrider19
Joined: 03 May 2016
Posts: 193
Location: Catawissa Missouri(40 mi sw of St Louis)
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| Posted: Fri Jul 29, 2016 7:15 am Post subject: |
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I just got that heat shield for mine on ebay. OEM new $24.00 with shipping.
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87 924S |
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jvandyke
Joined: 30 Mar 2016
Posts: 212
Location: Hudsonville, MI
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| Posted: Fri Jul 29, 2016 10:40 pm Post subject: |
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okay, found it, on ebay too
I'm going to maintain a list. Mark at Plyhammer set me up with a ton of stuff but some of it seems wrong and I'm sure I missed a bunch so I'll start a second list.
Currently working on getting the shift fork rod out of the bellhousing so I can put eyes on the release bearing and clutch.
Hopefully we can make the turn and start putting things back together instead of take them apart! Sure hope I remember where all the bits go!
We stopped to bling up the cam box yesterday.
Pretty cool. My son likes this stuff.
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87 924S project, '83 944 engine,
my son's first car. |
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hdrider19
Joined: 03 May 2016
Posts: 193
Location: Catawissa Missouri(40 mi sw of St Louis)
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| Posted: Sat Jul 30, 2016 1:27 pm Post subject: |
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Mine was rusted in place. I was able to get my bell housing off with it still in. With housing off I used a long thin punch and drove it out from the top down. Don't forget the small lock bolt on bottom side.
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87 924S |
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hdrider19
Joined: 03 May 2016
Posts: 193
Location: Catawissa Missouri(40 mi sw of St Louis)
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| Posted: Sat Jul 30, 2016 1:40 pm Post subject: |
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BTW I am mid 50s and I like the painted cam case too. I will post a pic of mine this weekend. Putting new timing belts and related parts on tomorrow.
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87 924S |
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jvandyke
Joined: 30 Mar 2016
Posts: 212
Location: Hudsonville, MI
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| Posted: Sun Jul 31, 2016 4:01 am Post subject: shift shaft stuck |
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I can't get this dude out.
Removed the locking bolt, threaded in an 8mm bolt and have been soaking in PB Blaster, prying on said bolt, beating on said bolt, cursing (in German) at aid bolt.
I'm doubting this is how it comes off??
I'll take a picture.
here's the top end of the shaft, can pound on this too I suppose?
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87 924S project, '83 944 engine,
my son's first car.
Last edited by jvandyke on Sun Jul 31, 2016 5:13 am; edited 1 time in total |
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