Hilton

This is curious.. I just pulled the rack of both my 928's, and found each car has different banjo bolts on the PS rack fittings.

The 89 has two bolts like that on the right, with the offset holes (both layers of holes fit completely inside the banjos)
The 87 has two bolts like the left - all the holes at the same distance along the shank.

Anyone have any idea why the factory would use two different designs?

PS I loathe those M10 lock nuts that sit on top of the crossmember and require a 5mm hex key to jam them just so I can undo the bolts. I'm tempted to turn the bolts upside down and screw the nuts on from below.

The Fixer

Hilton,

Don't know why they changed the hole position, probably for reasons having to do with steering feel.

Anyway regarding getting to those nuts:

I sacrificed an offset wrench and shaped it like a socket (on bench grinder) to fit down over the nut. As you know, a socket is too tall to get in there and a wrench will not fit due to the tight fit in there.
this modified wrench makes the removal very quick and easy.

Bilal928S4

I don't know why people have such trouble with those bolts.
I use a regular socket with this adapter
http://www.harborfreight.com/3-piece...aps-67011.html
and then use a gear wrench or regular wrench on the adapter. Works great once all the crap has been cleaned from the recesses of the cross member so that the socket is seated properly.
HTH

dr bob

I use either a flex-socket-head combination wrench, or a thin-walled socket with a stubby ball-end extension and a ratchet, or the same thin-walled socket in 3/8 drive with a short "breaker bar" flex-handle. The last option is easiest for me since those tools live in the tool-cart that rolls next to the car with me.

----

For my next big invention, I propose a cart with a pneumatic cylinder that raises and lowers the top section a couple feet. Short so it rolls under the car handily for use with the Max-Jax at 4 feet car height, or raise to 34" table height when not under the car.

ROG100

As the part number has superseded four times in the last few years I am not surprised it has changed. They found another number that would work even though it was slightly different.

The Fixer

They're easy but one, i couldn't fit that setup ^^ in the space.
The tough one of the four was the driver's side front.
The others were simple.

Vilhuer

$50 at local tool store. Works great.

Hilton

Three of the bolts are easy.. the problem one is the left-rear of the four, which on a RHD car is buried underneath the two PS hardlines and really awkward to get at. (our PS lines come down the wall of the engine bay in the same place as LHD, but then there are hard lines all the way across the rear side of the crossmember to the driver's side).

None of the tool suggestions so far would get to it on an RHD car without removing the high pressure and return PS lines from the rack and the wall of the engine bay, and dropping the crossmember an inch or so.

I had a good swear at that bolt this evening while putting my '87 back together

Vilhuer

Are you sure those swivel things don't work? I haven't seen RHD rack but there has to be some direction which has opening for the tool. Those can point downwards on very odd angles etc.

Hilton

I don't have a handy pic as the cars back on the ground so I can drive to work today.. but I'm putting it up on stands tonight to replace the remaining coolant hoses and the level sender so will take a pic.

Or just ask Sean to drop the rack on Roger's SE