924Board.org

[brealytrent]

As some of you know, last September my clutch stopped disengaging. After a looonnnggg winter, I've finally started the process of going about fixing this issue and as expected, it's turned into a rather large project. So lets all get updated!
























To start things off, a puppy! Her name's Perl (or Pearl, depending on what piece of adoption papers you look at) and she's a handful.




Started work on the car doing something simple, and that was replacing all the old rubber brake hoses. They were all original, and just waiting to become a problem later on.




RUST! If you cannot tell, this is on the left front side of the passenger footwell. I knew of the rust when I got the car, however it seems to have progressed since then to a full blowout. This is further encouraging me to replace all seals and whatnot into the passenger compartment as somehow, water keeps getting in there. I think it comes thru the sunroof as well as the blower motor (water drips out of the vent for your feet when it's pouring rain). Will get fixed in the relatively near future.




Side note: The Haynes manual is nearly worthless when talking about the removal of the clutch and etcetera. Here's what happened:




To get all the clearance I needed, I had to remove the transmission. something was keeping the whole system from moving back far enough to where I could get at the pressure plate and the rest of the clutch. All in all, if I had started out by removing the transmission, I would have gotten a lot further than I had. On another note, now that I've gone through all this trouble, I might just replace this transmission with one of those nice 5-speeds




Pic of the bearing down in the torque tube. Pretty sure it's the original bearings, but they seem to be working well still.





Pics of the clutch. It was stamped 2/77 which suggests to me that this is the original clutch. It's honestly in great condition, and was never a problem, but it is being replaced. You may notice some things tweaked on it however, which we'll get to later.





As you can see, there's a bit of oil in the bellhousing. I'm not sure if it's the rear main seal, however the area behind the flywheel appears free of any oil? The throwout bearing doesn't appear to be broken, besides one of the clips being broken off...





It appears the culprit of this was a $6 part - the pilot bearing. It's completely blown to smithereens, and must have caused the system to lock up. The spline on the torque tube looks unaffected however.

So that's where I'm at. Hopefully I'll have this thing back on the road by early May.
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1977 Porsche 924 - sold
1980 Porsche 931 - sold
1984 Porsche 928 'S2' Euro - sold
2016 Ford Fiesta ST - sold
2009 Porsche Cayman

[joemac]

The hound is adorable.

The ingress of H2o is likely from the battery box seam sealer leaking.

The bad pilot bearing can cause the mainshaft to lock to the flywheel, causing grinding in 1st & reverse.
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Race car: my favourite palindrome.
Porsche: my favourite race car.

[Grenadiers]

Once you pull the flywheel for refinishing, check where the oil pan and block come together right behind the flywheel, it might be leaking there. That is, if the rear main seal is fine.

Also, my battery tray was completely gone on the CGT project. Fixing it wasn't that hard, give me a hollar if you want the garage-logic version~!
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'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke

[brealytrent]

[fiat22turbo]

Following the oil line up the block you can see where it is leaking at the rear of the cam/valve cover/oil pressure sender area.

Time to pull that area apart and reseal it

Otherwise, have the clutch ground at a machine shop, and go read the how-to on replacing the pilot bearing, it's a lot of fun.
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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[Grenadiers]

hey Trent, I brought back a rust free complete 5-lug setup from an '83 944, including brakes. And have a spare 931 transmission. These are slated for my wide-body project, but, I can 'spare' them if you want. Not sure what to charge, pulling that suspension setup was tiring to say the least~!
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke

[brealytrent]

[Grenadiers]

Yup, we came back April 5th, just in time for 3 straight weeks of wet/snowy weather. Grrrrrr. We open the restaurant on May 17th. Waiting for spring so our builder can put in a second bar in our courtyard. And add more seating to the left side of the building.
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke

[brealytrent]

Removed the broken pilot bearing (as much of a bitch as all of you said it was)






new Pilot bearing, throwout bearing, guide sleeve, pressure plate, and clutch disk installed!





Gave the tranny a quick cleaning with some degreaser





Riveted in two pieces of metal (one inside, one outside) where the rust was. Cut out the rusty metal, riveted in, covered in body sealer and then undercoating (not pictured).





Much needed rebuilt starter installed!





Put her all back together, and she runs like a charm now! Also noticed there is no more clunk at shutoff anymore or when engaging the clutch. Unfortunately didn't get a 5-speed, but it's just that much more original now!
_________________
1977 Porsche 924 - sold
1980 Porsche 931 - sold
1984 Porsche 928 'S2' Euro - sold
2016 Ford Fiesta ST - sold
2009 Porsche Cayman