924Board.org

[TajMan]

I found the main leak coating LOTS of the underside of my '87 924S, Its the pressure hose between the PS pump and the rack-n-pinion

My question is what I can minimally remove to disconnect the fitting on the rack end.
Front sway bar partially or completely? Unbolt the rack-n-pinion from the chassis, and also have to unbolt the steering joint correct, are you able to move rack away enough to remove fitting? (you don't have to remove the two tie-rod-ends with a pickle fork and completely remove the rack do you?)
_________________
'87 924 S

[TajMan]

I'm at my shop!

just a quick word, what needed for power steering pressure line removal on the rack end?

thanks
_________________
'87 924 S

[fiat22turbo]

These might help:

http://www.clarks-garage.com/shop-manual/steer-02.htm

http://www.clarks-garage.com/shop-manual/steer-01.htm
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[TajMan]

some clarification for people searching,
to remove the fitting I believe it can be done with minimal removal:
a. partial removal of the front sway bar
b. unbolt rack from crossmember (4 bolts)
and steering joint can remain attached!

With that you should be able to move rack away enough to gain access when looking from the rear underneath back behind the front wheel, just over the top of the front crossmember, the allen-head fitting for that line.

BUT my fitting so tight, I stripped out the allen head using the correct size wrench! great


I got a dremel tool up in there and cut a straight line in the head of the (its a banjo bolt correct?)

but now I think there's no way I can turn that still tight bolt with a big screwdriver like that

because the whole rack is loose moving around, there's no way I can put enough pressure on it and turn at the same time!

So I just need some confirmation, if that's a banjo bolt I think I can cut the head off completely with the dremel tool, then with the pressure line itself removed and bolt tension off- I should be able to back out the rest of the banjo bolt with a pair of pliers?
_________________
'87 924 S

[jason c]

It should come out that way just don't grind deep enough to hit the line. If it were me, I would strike it with a chisel or screwdriver & hammer at the 3 o'clock position and at an angle to turn it. It works well.

[fiat22turbo]

I'd just use some vice grips, tighten the bolt slightly to break the tension and unscrew it (or break it off)
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[TajMan]

I've been having a nightmare trying to do this.
I'll post more and pics later, but basically that banjo bolt I cut was the WRONG ONE anyway, right next to the correct one..

I got them both off including the correct pressure line fitting.
The 2 banjo bolts are slightly different, the one I cut-removed used a rubber O-ring, the other one for the pressure line just used two copper crush washers.

Porsche parts department is really no help, they show two banjo bolts in that area that are both the same part number listed 999-134-018-02 and its #36 in the parts diagram..

Right now I don't know how to find new & replace that banjo bolt I cut, which uses a rubber O-ring on the bolt head side of the fitting, and it must use a crush washer on the other side of the fitting but I couldn't even find that when I removed..
_________________
'87 924 S

[TajMan]

Here is what the bolt looks like I cut, which was the wrong one, which I need to replace:





You can see how it is stepped, uses a rubber O-ring on the 'head' side of fitting, and I'm not sure if it uses (but it must) a copper crush washer on the opposite side of fitting to seal from leaks.

The other fitting on the pressure line itself just uses two copper crush washers, those are easy enough to replace..

I still need a new pressure line though!! Porsche wants $305 for a new line, The House of Hose can't help with anything! HELP!, anyone anything? I would even install a used part, but I need SOMETHING that will fix this cheaper than a $300 hose part.
_________________
'87 924 S

[jason c]

What's wrong with the line? If its just the rubber line, you can cut the shells (crimped clamps) that hold the hose on off. Put new shells & new hydraulic hose on and re-crimp it. Any hydraulic hose shop should be able to do it.

[Kens_74_911s]

have that HP hose here I still have this rack as well may be able to pull the banjo bolts from it.
http://forums.pelicanparts.com/porsche-924-944-968-used-parts-sale-wanted/789959-944-power-steering-parts-fs.html

Ken porscheken@nc.rr.com
_________________
Ken - ebay: wandrey1 , *0 , *00 , *01
74 911s widebody
96 BMW 750iL
99 BMW 328i
81 VW MK1-1.8 GTI, 5 spd Pickup
02 Explorer (wife's)
92 BMW 735iL Parting
84,85,86x3,87,944. 82-924,88-924s parted
68, 70, 72, 73, 911~ 70,73 914 past Pcars

[TajMan]

The line was old and leaking from the joint at one end where rubber line attaches to steel fitting.

I went to The House of Hose, they told me they could not do anything for me, that the one end with the 90* was too close to the fitting for them to re-build.

I ponied up the cash for a brand new aftermarket line and banjo bolt from 944online (866)-944-STUF

I am still confused, the one banjo bolt (wrong one I removed) used a rubber O-ring fitting and I didn't see a crush washer on the opposite side of fitting... even though the banjo bolts themselves are physically close enough to the same thing, M12 1.5 thread pitch.

The new bolts that 944online sells have a normal hex head because apparently the orig Porsche bolts aren't available anymore..
_________________
'87 924 S

[fiat22turbo]

I'm curious as to why you'd order from 944online versus some of the more established vendors? I've heard a few negative or neutral things about 944online in regards to their pricing and customer service.

Either way, I hope it solves your problem and gets you back on the road.
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[TajMan]

I did not know that..

I had posted on the 944online forum at the same time as this forum, because I needed part info asap and I knew the parts I needed were more 944 specific than 924 specific possibly.. they recommended me there to online store and a $129 option that seemed much better than any $295-$305 Porsche option I had found..
_________________
'87 924 S

[fiat22turbo]

http://www.pelicanparts.com/catalog/shopcart/944M/POR_944M_SUSstr_pg2.htm#item6
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[TajMan]

follow-up, I believe this pressure line DID in fact fix the power steering leak I had..
_________________
'87 924 S