924Board.org

[benlg81]

Hi All

Can you remove the fuel tank from an 82 2ltr 924 without having to drop the transmission?

Please say you can with tips!!!!!

Cheers

Ben

[agfisher]

Unfortunately, from what I've learned only the 1980 924 with the Snail shell transmission can have the fuel tank removed without removing the tranny. I have a 77 and just removed the fuel tank and there was NO way that was coming out without the tranny being removed first.

Adam
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1977 924 N/A Martini Edition

[benlg81]

gutted, how easy is it to drop the transmission?

[agfisher]

Someone else can chime in with something I forget.

This is what I ended up doing, YMMV.

1) Remove the final muffler assembly. Three bolts at the connector, and then four more (I think) along its length for support. The whole thing should drop at that point.
2) Next I dropped both axle shafts. Make sure you mark then Left and right and which end is in-board and out-board. This will be useful when reattaching or rebuilding. The axles are held on with 8mm(I think) triple square bolts. These are a special tool but you should be able to find them at a FLAPS. These bolts have a tendency to strip so take the drive and tap it in with a hammer, then attach the socket to loosen.
3) Crawl under the car to the front of the transmission and there should be an access hole. Remove the cover and inside you should see a coupler with two hex bolts. Remove both of these bolts and then slip the coupler into the transmission side of the shaft.
4) While underneath there, on the top of the transmission remove the shift linkage. It should have a rubber boot over it. Remove the boot and there should be a bolt that you can remove.
5) In the cockpit, remove the shifter cover and then remove the small C-Clip on the shift lever. Pull off the shift rod, rotate it about 90 degrees and slid it forward between the foam and the top of the hump. You need to slid it forward about 8 inches or so.
6) From the back of the transmission, remove the reverse light plug and then switch.
7) Now remove the four bolts connecting the transmission from the torque tube housing.
8) At this point the transmission is hanging by two bolts located on either side up top. This part can get hairy and it's helpful to have a friend help. Position a jack under the transmission. The balance point for the transmission is a the big flat spot. It doesn't look like it should be, but it is. While your friend mans the jack undo the two bolts and then lower the transmission to the ground.

At this point the fuel tank is an easy drop.

This is my recollection of how I just removed mine. The best thing to do is do some searches on this site and to go through the steps in the Haynes manual and/or Factory Manuals

Good Luck!
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1977 924 N/A Martini Edition

[ideola]

The most important thing to do when removing the trans is to remove the coupler FIRST before you do anything else. You have to completely remove both pinch bolts from the coupler. Take them ALL the way out and lay them on the ground or in a magnetic parts holder. Once you've done this, you should be able to slide the coupler toward the back of the car onto the input shaft of the gearbox. Do NOT slide it forward onto the driveshaft. Once the coupler is completely onto the input shaft, the rest of the removal process is very straightforward as described above. Dropping the trans is actually quite easy, I can do it in about 20 minutes or so.

Once the trans and exhaust are out of the way, the hardest part about removing the fuel tank is getting the electrical connections off because they're pinched in between the top of the tank and the underside of the hatch area bulkhead. In your case, you may not care about preserving the wiring harness, in which case, you can just cut the leads and yank the tank out.
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erstwhile owner of just about every 924 variant ever made

[agfisher]

[benlg81]

been on it for a while now undone the two star key screws inside the bell housing

taken off the driver shafts( well cut through the middle!)

undone the 2 hangers

undone all the bolts on the bell housing

taken out the shift rod

and parted it by an inch

but the thing wont seperate please help had it up and down and been pulling and pushing it like a mad man and still cant make the fecker split and land on my pallet please help!!!!

[Paul]

Did you slide the input shaft coupler back onto the input shaft of the tranny?
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

[benlg81]

i havent done that yet

i will jack up thea rear of the gearbox and then try and push it towards the back of the car

[ideola]

[agfisher]

Yeah you have to get that coupler ALL THE WAY back towards the back of the car for it to drop. Reattach the bolts hold the tranny to the bell housing and the bolt into the car body. Then slide the couple to the rear of the car as far as it can go. Then remove the belts and it should be able to drop.

Adam
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1977 924 N/A Martini Edition

[benlg81]

gutted

a r s e about face again i will try again later today

Cheers

Ben

[DZGunner]

[agfisher]

I have a '77 and have never removed the fuel tank in an '80. I do have a couple of questions though. What have you done on the top side of the tank? Is there filler hose disconnected? Can you get an idea from wiggling where it is hitting/catching?
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1977 924 N/A Martini Edition

[DZGunner]