Warning to all 928 owners! - Check your headlight clips, upgrade solution post #119
12-27-2006, 11:25 PM
#61
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Join Date: Sep 2006
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I'm thinking about drilling the shaft and putting in cotter pin? Do you think that the motion of the arm would work on it, or that the washer would protect it?
12-29-2006, 12:12 AM
#64
Rennlist Member
Originally Posted by Nicole
Should these joints ever be lubricated?. If so, what to use?
It would make sense that friction between the clips and the washers that the lack of lubrication would create would turn the clip every time that the lights were actuated, and weaken them.
If there never was lubrication, there should have been.
A dab of lithium would likely be fine.
12-29-2006, 05:59 AM
#65
Drifting
Even more catastrophic would be to have your fingers sliced off by the mechanism. The motor can and will start if you unplug the connector, move the motor by hand, and then reconnect. Beware!
06-20-2009, 07:02 PM
#66
Drifting
updating this old thread with new info...
I used locking clips which are also used on the automatic's shift lever.
Porsche P/N: 999.166.005.02, sl-lock
But in the case of my 90' S4, I needed to modify the nylon bushings slightly. It’s a good idea to remove the linkage anyway and apply a new coat of white grease.
After removing the old clips, washers, the linkage comes off without any movement of head lights.
I used medium grit sand paper to sand down the nylon bushings which are slightly too thick to accommodate the new clips. You can cut the sheet of sand paper in half. One side up the other side down on a flat surface and sand until the thickness is about 8.25mm. Mine measured 9.00mm on removal from the car. I went down to 8.00mm, but 8.25mm is probably just right.
Assembly is easy. Once installed make sure you have the clip properly locked on. With them locked on, you should be able to rotate the clip with just your fingers, otherwise its probably not on all the way.
I used locking clips which are also used on the automatic's shift lever.
Porsche P/N: 999.166.005.02, sl-lock
But in the case of my 90' S4, I needed to modify the nylon bushings slightly. It’s a good idea to remove the linkage anyway and apply a new coat of white grease.
After removing the old clips, washers, the linkage comes off without any movement of head lights.
I used medium grit sand paper to sand down the nylon bushings which are slightly too thick to accommodate the new clips. You can cut the sheet of sand paper in half. One side up the other side down on a flat surface and sand until the thickness is about 8.25mm. Mine measured 9.00mm on removal from the car. I went down to 8.00mm, but 8.25mm is probably just right.
Assembly is easy. Once installed make sure you have the clip properly locked on. With them locked on, you should be able to rotate the clip with just your fingers, otherwise its probably not on all the way.
Last edited by borland; 10-28-2010 at 11:00 PM.
06-20-2009, 07:35 PM
#70
Burning Brakes
This is great info and a great update. Before reading this thread when it was first posted I had no idea of this being a issue, and sure enough I was missing the clips.
Saved my ***.
Saved my ***.
06-20-2009, 09:45 PM
#72
Not the sharpest tool in the shed
Rennlist Member
Rennlist Member
Great repost of a common problem many of us newer 28 owners did not know existed. Probably saved a radiator or few as well as the frustration.
06-20-2009, 10:11 PM
#73
Rennlist Member
Great idea to keep this info fresh and relevant... I immediately checked mine! Both clips were still there (whew!). I think I will still get those tranny shifter clips to keep in case of an emergency. Thanks for the tip! 
