 Rebuiding Inside-out |
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| bkrantz |
 Dec 14 2021, 08:23 PM
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#4321
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914 Guru  Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains 
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I then explored the options for spacers, washers, and retaining clips. This would be the stock set-up.
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| bkrantz |
Dec 14 2021, 08:23 PM
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#4322
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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New conical washer on the shaft, and some grease on the splines.
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| bkrantz |
Dec 14 2021, 08:26 PM
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#4323
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I pressed the CV onto the shaft, and then used split ring pilers on the stock type circlip.
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| bkrantz |
Dec 14 2021, 08:28 PM
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#4324
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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But the CV center partially blocks the groove for the clip. I tried using my press to squeeze the conical washer down but that did not work.
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| bkrantz |
Dec 14 2021, 08:30 PM
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#4325
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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The CV kits also include a thinner snap ring.
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| bkrantz |
Dec 14 2021, 08:31 PM
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#4326
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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That fits nicely, but could be weaker.
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| bkrantz |
Dec 14 2021, 08:33 PM
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#4327
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I pressed the CV off the shaft.
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| bkrantz |
Dec 14 2021, 08:34 PM
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#4328
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I pressed the CV off the shaft.
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| bkrantz |
Dec 14 2021, 08:35 PM
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#4329
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I pressed the CV off the shaft.
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| bkrantz |
Dec 14 2021, 08:36 PM
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#4330
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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And then I dug out the conical washers from the original CVs. These were already a bit flatter than the new ones, and I encouraged them to be even flatter.
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| bkrantz |
Dec 14 2021, 08:39 PM
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#4331
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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Comparison of the flattened washer (top) and the high-relief new washer (bottom). My measurements are close to fitting with the thicker circlip.
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| bkrantz |
Dec 14 2021, 08:41 PM
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#4332
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I then took a look at the new boot and flange. These are also essentially type 1, with 6 bolt holes.
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| bkrantz |
Dec 14 2021, 08:44 PM
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#4333
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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But what I don't like is the sloppy fit. The OD of the outer part of the CV is 90 mm, but the ID of the flange is about 94 mm.
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| bkrantz |
Dec 14 2021, 08:48 PM
Post
#4334
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I thought about a stock paper gasket on the inside of the flange, but this would prevent metal-to metal contact of the boot flange and leave some compressibility in the stack.
I ordered some 90/94 mm O-rings to try another way. Attached thumbnail(s) 
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| bkrantz |
Dec 14 2021, 08:52 PM
Post
#4335
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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Then I got out the trans mounts. More re-plated stuff and new rubber mounts.
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| bkrantz |
Dec 14 2021, 08:54 PM
Post
#4336
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I also took the chance to set up the muffler and bracket on the rear of the trans. (And the trans mount bolts are upside down for now.)
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| bkrantz |
Dec 14 2021, 08:58 PM
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#4337
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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This was also a chance to double-check the O2 sensor bung location. It still looks good, since I am not using the stock muffler hanger. But for good sensor clearance the bung needs to be horizontal.
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| bkrantz |
Dec 14 2021, 08:59 PM
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#4338
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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Looks good, so off to the welder.
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| bkrantz |
Dec 14 2021, 09:01 PM
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#4339
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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Final bit for today: bolt on the trans mounts, with the bolts correct (inserted from below).
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| bkrantz |
Dec 15 2021, 08:21 PM
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#4340
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914 Guru Group: Members Posts: 8,347 Joined: 3-August 19 From: SW Colorado Member No.: 23,343 Region Association: Rocky Mountains
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I got distracted by a few other things today, including shoveling snow.
But I think I have decided where and how to mount the ECU and relay box. Attached thumbnail(s) 
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