944 89 Engine, gearbox transplant...

[Crank Case]

Day 18 and a half...

Finished off the last bits on the back end after all the Dinitrol removal, sorting broken studs, grommet brackets etc
Porsche shop uk have finally dispatched the clutch bearing sleeve. Fingers crossed, it will be here tomorrow.

Wish i'd taken more before pics...

From this:





To this:

[Waylander]

No shortage of black stuff under there, I love work, I could sit and watch all day

[Crank Case]

Just like my cat.

There's a helluva lot less black stuff there now.
Even my bananas are shiny*.

*There's a joke in there somewhere.

[Waylander]

Not had a chance to even look at the car, even though I have a gearbox mount to fit

Been fitting fences, new work bench in the shed trying to fit in between the torrential showers, the Mrs crashed the XC60 at about 15mph on Monday, the seat belt tensioner fired and cracked two ribs and put a seat belt wide bruise right across her torso, and it’s really black n blue, cars hardly touched, but 2.2 tons of Volvo does not do a 68 plate micra any favours at all

[Crank Case]

...but 2.2 tons of Volvo does not do a 68 plate micra any favours at all

ROFL (I shouldn't laugh really)

I hope she is okay.
That's one tetchy safety system.

Eons ago, my mate came flying around a corner in his mini (as you do) and there was nothing at the brake pedal. He had a split second decision - a skip or a Volvo was the choice. He hit the Volvo. Wrote off the mini completely. Volvo had a bent bumper. He said he wished he had hit the skip.

[Crank Case]

Wahey!

The engine is in (after some huffin' an' puffin'). Can't find the bloody hoe clip for the water pump hose...

It's all wired up. Even sorted the clutch slave, filled it and bled it.
Without assistance, it required use if a drip tray and a heavy weight - i'll leave it to your imagination.

FWIW, the bolts I bought for the lower steering knuckle ball joint fitted perfectly - no float.

Tomorrow, it's time to fit the gearbox, fuel filter/pump assembly, exhaust and the last bits and pieces. It's great to work on the engine and stay clean all the time.
After fluids and connecting the battery, I might even try and start it!

[Waylander]

You know H is going to be very jealous,

Well done Rob impressive work, thank the virus it’s helped you get it done

I’m still waiting for a throttle cable and a micro switch, as no one other than Porsche them n stock

So I might have a go at the gearbox mount tomorrow

[Crank Case]

Yeah cheers.Nearly there. At this slow (but inexorable) rate, I think I am looking at Wednesday before trying to start it... It will be a bit of heart in the mouth moment.

That gearbox mount.
Did you get this version?



I bought this one on recommendation from Geo. Morrison, Glasgow. It's a bit of a fiddle. If you haven't done it before, to get some clearance, support the box and drop the cross member by unscrewing the bolts a little.
If you support the box but accidentally screw one out, then you're ok.

Door micro switch? I have a spare if you're stuck.

Had to order some new cable ties from partworks.de for the cable route along the bulkhead. Glad they're available.
Any news when Porsche are 'opening up' supply lines? It was meant to be last week according to 9 Apart.

[Waylander]

No idea when they will open, the micro switch is for the clutch pedal for the cruise control along with the short throttle cable,

The 968 gearbox mount is completely different to the 944, you might regret that mount as the noise transmission will be loud, those type appear to be used on race cars mainly

I have a picture somewhere with all the cable ties and clips and other things laid out on a board with part numbers

[Largie]

No shortage of black stuff under there, I love work, I could sit and watch all day

A Jerome K Jerome quote!

David

[Crank Case]

The 968 gearbox mount is completely different to the 944, you might regret that mount as the noise transmission will be loud, those type appear to be used on race cars mainly

I've lived with it for over 18 months.
Transmission noise drowned out the racket from the rest of the car!

Now it's all fixed (sort of), I have treated myself to an original.

Today was spent wrestling with the gearbox. I had it all figured out. I think it's harder to fit than the engine.
Perhaps i'll get the angle grinder to the wheel well.

Page 203, Volume 5 electrics, square L something... (I think i'll get my printer mate to print off the whole wiring diagram in A3).
Have I really got 3 leads on the one starter motor M8 lug? ...or have I missed something?
Can you get under your car and have a look for me H? Ta

[Waylander]

That is correct


Battery lead
Abs lead
Alternator lead

8mm is the solenoid power wire

And I have had the same fight, took me 2 hours to get the mount off, think it will take the same time to put it back

Still not as hard as the oil filter housing with the engine in the hole

[Waylander]

Gearbox mount on a 968 = nightmare

[Crank Case]

Gearbox mount on a 968 = nightmare

,

When I do that mount, I won't have the drive shafts connected and the cross member will be loose but bolted in. I'll report back if it turns out to be easier.
Does the original mount have captive nuts?

I had to get another clamping sleeve (gearbox to TT). Could not line it up despite all bell housing bolts in place. I may have opened it up on extraction of the old one in a slightly ham fisted way due to the tilt required. My mistake but for love nor money could I get the thing to squeeze together in the vice and get the splines to work sufficiently freely to be able to connect it through the inspection hole.

Another wait for parts. Tomorrow will be putting the power steering rack together now i've got everything. Something I wasn't looking forward to but anything not underneath the box currently will be a holiday.

[Waylander]

Think the 44 will be easier,

Everything was in the way, exhaust, heat shields, driveshafts, fuel filter, reverse light switch,

Then getting the mount off the two roll pins was a pain in the, and getting it lined up again even harder, one bolt holds the mount to the gearbox, can’t reach it from below too much in the way, can undo it with the longest extension ever, trying to put it back in when my arms were about 3inches too short,

Real pain in the