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> Rebuiding Inside-out
bkrantz
post Dec 28 2020, 08:05 PM
Post #1821


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Finishing up the relay board. The potting compound looks pretty solid after 36 hours.

And some leaks, from over-filling.


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bkrantz
post Dec 28 2020, 08:06 PM
Post #1822


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Compound leaked through the side notches, and onto one of the 12-pin sockets.


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bkrantz
post Dec 28 2020, 08:07 PM
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And the compound found more leak points, including the pins of the other 12-pin socket.


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bkrantz
post Dec 28 2020, 08:08 PM
Post #1824


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And the 3-pin socket, and one tab for the fuses.


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bkrantz
post Dec 28 2020, 08:10 PM
Post #1825


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And the 4-tab socket. Damned stuff was very sneaky.


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bkrantz
post Dec 28 2020, 08:11 PM
Post #1826


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At least the wax in the big holes worked.


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bkrantz
post Dec 28 2020, 08:12 PM
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And was easy to clean out with a tooth pick, Q-tip, and 3M solvent. I also scraped the compound off the other pins and tabs where it leaked through.


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bkrantz
post Dec 28 2020, 08:16 PM
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Ready to go!

A few lessons:

To fill the underside takes 70-75 ml. Any more will overflow.

The wax worked to fill the big holes, but a thin compound will find a way through other small holes.


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bkrantz
post Dec 28 2020, 08:18 PM
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One more task done today: a new shift rod bushing in the firewall.


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bkrantz
post Dec 28 2020, 08:21 PM
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This was a bit difficult to install. I tried pressing with a 2x4 levered against the car dolly frame without success. With a step-down spacer and big hammer, I was able to get it most of the way in, and finished with a pry tool against the inner lip.


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bkrantz
post Dec 29 2020, 07:40 PM
Post #1831


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Next, mounting new air deflectors.


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mb911
post Dec 29 2020, 07:42 PM
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@bkrantz there was something that left here today for your project.
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bkrantz
post Dec 29 2020, 07:42 PM
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Three holes on the right side, that match the center and end holes on the deflector.


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bkrantz
post Dec 29 2020, 07:45 PM
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And 3 holes on the left. Note the parking brake tube blocks the left end hole on the deflector. Instead, the deflector has a 4th hole offset from the left end.


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bkrantz
post Dec 29 2020, 07:48 PM
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The bolts screw into under-sized holes in the plastic deflectors. It helps to "thread" these holes before mounting.


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bkrantz
post Dec 29 2020, 07:49 PM
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Left side in place.


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bkrantz
post Dec 29 2020, 07:50 PM
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And right side.


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bkrantz
post Dec 29 2020, 07:53 PM
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Note the factory manual has a page about mounting the deflectors.


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bkrantz
post Dec 30 2020, 07:56 PM
Post #1839


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A couple of weeks ago, before installing the wiring harness, I added a switch (from CarMagic) for a new washer pump to the steering column sub-harness.

I had also ordered a plug connector so the switch can detach from the harness if I ever need to pull the column control stalk module. Here is the connector installed.


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bkrantz
post Dec 30 2020, 07:56 PM
Post #1840


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Half the connector stays with the harness.


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