Big Dave

Out of the four I tried to remove, 3 broke off (sorry Kevin). The others started to turn but felt too similar to the ones that broke so I left them alone. A 75% snap rate is nothing I want to increase.

I managed to get one out: it's a 13mm bolt that fits under the cam cover and secures the cam cover bolts to the head. I believe there are twelve for each head.

Any know the part number? I'll need 24 thank you, since the one I pulled doesn't want to screw into my replacement heads.

Anyone else had the same problem? PB Blaster didn't help at all.

DR

Unfortunately very common, so common that Porsche discontinued those "spacers" and short retainers and has replacements designed like the improved S4 version.

Part numbers you need are 928.104.481.17 (long - 18 total for both sides) and 928.104.481.18 (short - 6 total used for both sides).

However they are insanely priced, currently $29 and change EACH! Yes, $29 for a silly bolt.

This is one part that some of your machinest guys should really make for us. I have some in stock and would happily provide samples.

Big Dave

Time to start looking for a local machinist. That's crazy.

sharky47

Hey guys, PM me and send me a fastener of both lengths. I am a CNC programmer and may be able to help!!!

Big Dave

I don't know what a CNC programmer is. Does it mean you have the ability to fabricate stuff?

Garth S

That means that he is the answer to your prayers!! Computer mapped and controlled machining: once the program is set, cookie cutter perfection starts - kind offer sharky!

sharky47

Yes, I can have that part running in a couple of hours. Send me a sample of both lengths and I will see about getting a small run (~1000) made. The owner of the company is a family friend, he as already told me he would make me a special deal on parts that I want to run for myself. I can make it out of a better/stronger material and hold a +/- .0003 tolerance if need be.

Big Dave

Daniel:

That's fantastic. I suppose we'll wait until DR responds, but it sounds like he's all for it from his previous post. He'll have to send you the samples.

I am curious, though, whether it is a good idea to make the spacers too if you can do it with a stronger material.

Do you have any idea what kind of pricing we're taking about here? I was thinking this morning that I might check with a local metric fastener supplier about whether they have bolts of the proper length and thread pitch in stock. If the bolts are torqued properly, there shouldn't be a problem with squashing the cam cover gaskets, right?

AO

Another benefit of rennlist! You're a lucky man Dave.

DR

Daniel,

Check your e-mail.

FYI, Here is a quick photo of the culprits

Big Dave

No ****. I was looking at $600 for friggin' bolts. No thank you.

Crackhead944S

Sharkey47 may already have those bolts holding his cam cover down. I want to go home and see if I can find a 928 part number on mine now. I'm pretty sure that my timing chain tensioner had a 928 part number and the picture of the offending bolts look exactly like the ones holding my cam cover down.

Jim bailey - 928 International

Dave what you discovered is one of the design flaws of the 1985-1986 4 valve engine. The spacer bolts have caused much grief. The typical scenario is the camcover gaskets are leaking so someone TIGHTENS the cover bolts a bit , they still leak so they get tightened some more. Eventually someone decides to remove the cam covers and install new gaskets BUT when the hapless mechanic loosens one of the cam bolts ....the spacer bolt shears off in the HEAD 1/2 of the time it is in a location where you can not get in with a drill to get out the broken bit. The plot thickens because the 85-86 block still uses head studs which means it is basically impossible to remove the head with the engine in the car (1987 and up used head bolts). So what started out as a minor oil leak is now REMOVE the engine to repair the broken bolts.....figure $1,500 or so LABOR plus the new updated bolts.....

Big Dave

Well, Jim, my heads are out already along with the engine. I've got replacement heads ready to install. I found this wonderful flaw as I was moving the fasteners from the old heads to the new ones, cleaning the bolts along the way. The replacement heads have clean, empty holes waiting for whatever fasteners I get. The old heads have 3 sheared off spacers, one empty hole and 20 spacers waiting for the next person to shear them off. Again, my apologies to Kevin (86.5_Tiburon) if he's watching this. I'm curious if the same thing happened to him when he was reconditioning the heads he sent to me.

P.S. I guess this little "gotcha" would be good to add to my engine rebuild web pages. It's time for an update anyway.

heinrich

SHARKEY: Please put me down for 2 sets <edit> actually I could use 20 sets if the price is right. Btw how about making a bunch of stainless steel fasteners that are unique?
Heinrich