|
"Everything at the Back" - rebuilding rear suspension
'87 S4 Automatic
I am in the process of doing "Everything at the Back", using Dwayne's write-up on replacing the Torque Tube bearings as a guideline. The plan is: 1. Remove and overhaul fuel tank and lines; 2. Remove Torque Tube and transmission. 3. Install super bearings in Torque Tube 4. Remove and overhaul rear suspension 5. Replace all fuel lines from rear to front. 6. Install Torque Tube, transmission, rear suspension and fuel tank. At the moment, the rear of the car is "empty": https://cimg7.ibsrv.net/gimg/rennlis...78cdba279c.jpg Still need to do a bit more cleaning, but have already tried to use dry ice: https://cimg0.ibsrv.net/gimg/rennlis...5e02988c20.jpg It was deafening, but the result was quite nice! I will try to post my 'journey' in different posts, hoping that any questions I come up with stay with that specific part of the job. It may also help for future searches by anyone who wants to try these jobs as wel....:corn: To make sure I keep track of what I do I made these 'books' with copies from PET, write-ups from Dwayne and other Rennlist heroes as well as copies of relevant pages in the WSM: https://cimg6.ibsrv.net/gimg/rennlis...892b4eb3a3.jpg Below are the pages in PET that I used to keep track of what parts I ordered, and also which parts are NLA. Some have new part numbers: wherever applicable I wrote the new part number next to the old one. Every "orange colored" part I ordered and is still available, every yellow part in the red boxes is NLA. Parts that are not colored I just did not (try to) order: https://cimg2.ibsrv.net/gimg/rennlis...c0b292dcee.jpg 501-00 new part number: Nr. 14 was: 900 082 140 01 now: N010 183 3 https://cimg7.ibsrv.net/gimg/rennlis...5629f90c29.jpg 502-00 new part numbers: Nr. 17 was: 900 910 046 02 now: 999 084 445 01 Nr. 26 was: N 010 472 4 now: 900 074 375 01 Nr. 28 was: N 010 445 2 now: 900 074 372 01 https://cimg8.ibsrv.net/gimg/rennlis...3a3a3281eb.jpg 603-00 new part number: Nr. 26 was: 999 075 005 09 now: 900 378 030 01 https://cimg0.ibsrv.net/gimg/rennlis...1917a4fba3.jpg https://cimg2.ibsrv.net/gimg/rennlis...c4ee5e4fa3.jpg And one more, showing the brackets that are attached to the cross member for the exhaust system: https://cimg5.ibsrv.net/gimg/rennlis...303d208026.jpg This is what my rear suspension looked like after we removed it from the car: https://cimg7.ibsrv.net/gimg/rennlis...46ada3d402.jpg https://cimg8.ibsrv.net/gimg/rennlis...3d0e42dd08.jpg https://cimg9.ibsrv.net/gimg/rennlis...b339fa042c.jpg I started to take it apart: https://cimg9.ibsrv.net/gimg/rennlis...36fb5ddf52.jpg https://cimg3.ibsrv.net/gimg/rennlis...5376ac0701.jpg Removing the exhaust brackets (one of them refused to come off without some brutal force...:to_order: https://cimg2.ibsrv.net/gimg/rennlis...cbb7e44954.jpg https://cimg7.ibsrv.net/gimg/rennlis...176cc87fe1.jpg Next the 2 brackets for the ABS wiring harness: https://cimg4.ibsrv.net/gimg/rennlis...7b0fc54e1d.jpg https://cimg5.ibsrv.net/gimg/rennlis...8ddbe8e984.jpg And next the hand brake cables: https://cimg7.ibsrv.net/gimg/rennlis...83ffa92578.jpg https://cimg9.ibsrv.net/gimg/rennlis...df736806ef.jpg Make sure to save the bracket that is attached to the handbrake cable mount, as it is NLA: https://cimg0.ibsrv.net/gimg/rennlis...7bb4054501.jpg Here is the hub assembly detached from the cross member: https://cimg4.ibsrv.net/gimg/rennlis...4aabfb6fdc.jpg A 'line up' after the wheel hub, bearing and ABS sensor (which were completely stuck on both sides and a nightmare to get out...) were pressed out of the wheel carrier: https://cimg5.ibsrv.net/gimg/rennlis...469ba9bc4b.jpg And finally everything is apart and ready for "treatment": https://cimg1.ibsrv.net/gimg/rennlis...1463fe6472.jpg https://cimg2.ibsrv.net/gimg/rennlis...352c759699.jpg https://cimg3.ibsrv.net/gimg/rennlis...d201137929.jpg The results and first rebuild attempts will be in the next post...:D |
Part 2:
Next job was sending out all parts that needed to be treated.
Here is the result (including the gas tank strap, Torque Tube and new springs....:burnout:) from the powdercoater: https://cimg3.ibsrv.net/gimg/rennlis...0232040817.jpg ....from nickel plating: https://cimg5.ibsrv.net/gimg/rennlis...4d37014111.jpg ...and from soda blasting: https://cimg6.ibsrv.net/gimg/rennlis...20f0a028ea.jpg Finally we were able to do some assembly work...!!! These next pictures are taken at the workshop of Bob Botter in Mijdrecht, an excellent mechanic and absolute genius with Porsches: https://cimg5.ibsrv.net/gimg/rennlis...f2e8b46758.jpg Pressing in new rubbers: https://cimg4.ibsrv.net/gimg/rennlis...c6f1385151.jpg Wrong car in the background, I know.....:evilgrin: https://cimg5.ibsrv.net/gimg/rennlis...b27b225ad7.jpg https://cimg6.ibsrv.net/gimg/rennlis...d1ad3ac1d2.jpg The next job was putting in the new wheel bearings into the wheel carriers: https://cimg5.ibsrv.net/gimg/rennlis...6ee47955f2.jpg https://cimg6.ibsrv.net/gimg/rennlis...770b2f3928.jpg A little bit of "Tool Porn"......:jumper: https://cimg7.ibsrv.net/gimg/rennlis...2154d48507.jpg https://cimg8.ibsrv.net/gimg/rennlis...3a64365e52.jpg https://cimg0.ibsrv.net/gimg/rennlis...c9a0192eb0.jpg Having fun with my dad....: https://cimg3.ibsrv.net/gimg/rennlis...64d1591edb.jpg Done! https://cimg8.ibsrv.net/gimg/rennlis...1d04f9f144.jpg time to put together the hand brakes. First we put on the refurbished supporting plate (928 352 081 01, NLA) https://cimg3.ibsrv.net/gimg/rennlis...3704b89a3a.jpg Attach the push-lock button to the hand brake cable, but before you do that make sure to slide the support bracket (701-10, nr. 24 - 928 424 045 00) onto the cable!!!!!! We forgot it, so may have to take it all apart again...:banghead: https://cimg4.ibsrv.net/gimg/rennlis...7080c3662c.jpg Installing the rest of the hand brake parts went smooth, apart from the 2 compression springs that have to be put in from the back side of the carrier. It took quite a while and the help of a large nut and a pair of pliers to get them through (too?) narrow slots.... https://cimg5.ibsrv.net/gimg/rennlis...357c49e911.jpg https://cimg9.ibsrv.net/gimg/rennlis...13a5e7d60f.jpg Putting in the wheel hub also became a bit of a challenge, as having it nickel plated increased the diameter of the hub slightly: https://cimg2.ibsrv.net/gimg/rennlis...cd08b2a19f.jpg Final job for the day was inserting the new ABS sensors. We lightly coated them with a substance that consists of ground marble. I had never heard of it, but it makes sense: any other grease will melt under higher temperatures, whereas this stuff can handle temperatures up to 1200 degrees celcius.... https://cimg2.ibsrv.net/gimg/rennlis...9ffc06a082.jpg https://cimg4.ibsrv.net/gimg/rennlis...b04ef28775.jpg https://cimg6.ibsrv.net/gimg/rennlis...875cbda309.jpg DONE! Next job will be shock absorbers and springs, hope to have that done next friday.....:cheers: |
Stunning. :bowdown:
Keep up the good work. |
Impressive, well done!
:cheers: |
Very nicely done.
Good time to get the rear main seal on your engine too. |
Cool, nice work!
|
Nice...
Does the brake shoe retaining spring go in from the back? |
Looks great!
Respectfully, you might want to double check those compression springs on the hand brakes. I could be wrong but I think you installed them backwards. I believe they go in from front to rear, aka, the coil part of the spring should be facing the wheel. The carrier has some ridges where the hook grabs ahold. I use a needle nose pliers in the middle of the coil, insert through slot, push and turn till the hook is on the ridge of the carrier. Oops, Glen beat me to it. Enzo |
https://cimg0.ibsrv.net/gimg/rennlis...c1df0b0fdd.jpg
These parts look stunning after the plating and soda blasting - it's an inspiration! They look like jewellery. I was also puzzled by reference to spring being inserted from rear. Here's a photo from John Pirtle's 928 S4 site showing it correctly positioned on the wheel side of the hub (but nowhere near as clean as your's!). |
Originally Posted by GlenL
(Post 14649470)
Does the brake shoe retaining spring go in from the back?
Originally Posted by Ladybug83
(Post 14649492)
Respectfully, you might want to double check those compression springs on the hand brakes. I could be wrong but I think you installed them backwards. I believe they go in from front to rear, aka, the coil part of the spring should be facing the wheel. The carrier has some ridges where the hook grabs ahold. I use a needle nose pliers in the middle of the coil, insert through slot, push and turn till the hook is on the ridge of the carrier.
Oops, Glen beat me to it. Enzo When I took it all apart it all seemed so logical so I made pictures but did not write down the exact direction for installing them. Looking at the relevant PET page again I understand why I was under the impression they had to go in the way we put them in. Will have a look at it tomorrow and hopefully I can turn them around. Thanks again, this is a big help! |
Originally Posted by Bertrand Daoust
(Post 14649007)
Stunning. :bowdown:
Keep up the good work.
Originally Posted by SwayBar
(Post 14649034)
Impressive, well done!
:cheers:
Originally Posted by SeanR
(Post 14649262)
Very nicely done.
Good time to get the rear main seal on your engine too.
Originally Posted by Tom in Austin
(Post 14649311)
Cool, nice work!
Thanks Guys! Sean, after completing the back the plans to lift the engine and do all the work at the front! So that seal will definitely be done... :-) |
Nice work!
|
You can also use a big flat screwdriver to push the spring in.
https://cimg1.ibsrv.net/gimg/rennlis...11a5ae0dad.jpg The spring should hook to the back like this: https://cimg8.ibsrv.net/gimg/rennlis...ada25833b8.jpg |
Originally Posted by StratfordShark
(Post 14649549)
https://cimg0.ibsrv.net/gimg/rennlis...c1df0b0fdd.jpg
These parts look stunning after the plating and soda blasting - it's an inspiration! They look like jewellery. I was also puzzled by reference to spring being inserted from rear. Here's a photo from John Pirtle's 928 S4 site showing it correctly positioned on the wheel side of the hub (but nowhere near as clean as your's!). |
Originally Posted by Bertrand Daoust
(Post 14650905)
You can also use a big flat screwdriver to push the spring in.
https://cimg1.ibsrv.net/gimg/rennlis...11a5ae0dad.jpg The spring should hook to the back like this: https://cimg8.ibsrv.net/gimg/rennlis...ada25833b8.jpg Thank you for that, Bertrand: we used something similar today, worked wonderfully...!!! |
| All times are GMT -3. The time now is 05:01 AM. |
© 2024 MH Sub I, LLC dba Internet Brands