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Little mishap during removal of TT & Transmission

 
Old 06-07-2016, 03:36 AM
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Smitje 928
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Default Little mishap during removal of TT & Transmission

'87 S4 Auto

Yesterday we removed the torque tube and transmission. It was a hard struggle, as the upper bell housing bolts were frozen and we just couldn't get them out. The only option was to leave the upper bell housing in place, but that meant we had to remove the bracket that attaches the bowden cable to the upper bell housing. And yes, also that bolt wouldn't come out. It took a blade of an iron saw and a lˇt of sawing from the top of the engine bay to cut the bracket in half.

In order to slide the torque tube and transmission backwards we had to lower the transmission. I made a special 'cradle' on a pallet so everything was ready to go:



My dad was in charge of the jack, and instead of lowering it a bit he accidently lowered it all the way, ripping the connector off of the transmission wiring harness that wasn't taken out of the battery area yet.....:-(
He was in shock, the poor man nearly lost it when he realised what happened. I've told him not to worry, and that we would find the necessary parts. And that is where I need your help: what is the part number of the wiring harness that is shown on the picture below? It ends in what appears to be a sensor of some sort at the back end of the differential:



As you can see the connector is ripped off, and can not be re-used. I've checked my version of PET and can't seem to find it.

Also, does anyone know the part number of the bracket that attaches the bowden cable to the upper bell housing? I can't find it on any of the relevant pages in PET....

Last edited by Smitje 928; 06-07-2016 at 02:24 PM.
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Old 06-07-2016, 04:53 AM
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G.P.
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Looks like the pulse sender for the speedo. 928 606 210 01
You could just join the wires together again, or someone like 928 International or Pelican should have second hand or maybe new ones.
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Old 06-07-2016, 06:45 AM
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Thanks a lot, G.P. ! That seems to be the right part...!!!
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Old 06-07-2016, 05:53 PM
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I have two spare ones if you need one, PM me. Doesn't look too bad!
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Old 06-08-2016, 06:03 AM
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Thanks for the super nice offer! I┤m still waiting on news from my parts supplier if it still available. If not i will definitely send you a PM...!!!!

Does anyone have an idea of the part number of the bracket that connects the bowden cable to the upper bell housing?
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Old 06-08-2016, 10:03 AM
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It's too late to help, but what did you try for the upper bolts?

I got a 3/8" flex-head socket wrench just for this job. Add a 6-point 19mm socket and then 3' of iron pipe to get enough torque. Make sure it'll clear the hood and pull. Hard.
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Old 06-09-2016, 05:50 AM
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I cut the open end of a wrench and used a piece of pipe as extra leverage. Unfortunately the wrench slid off when pulling the pipe, thus damaging the corners of the bolt on one side. We've tried many alternatives but it was just impossible to get it loose.

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Old 06-09-2016, 05:58 AM
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You got to really want that bolt off when your tools start getting donated to the cause.
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Old 06-09-2016, 06:45 AM
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Originally Posted by Smitje 928 View Post
Thanks for the super nice offer! I┤m still waiting on news from my parts supplier if it still available. If not i will definitely send you a PM...!!!!

Does anyone have an idea of the part number of the bracket that connects the bowden cable to the upper bell housing?
That bracket is sold as part of the bowden cable. Perhaps 928 Intl can slip one off a used cable.
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Old 06-09-2016, 11:31 AM
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I bought a set of the Ez-Red wrenches off Ebay for the bell housing bolts. They work wonderfully. It was worth the money.
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Old 06-09-2016, 12:23 PM
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Looks like the OP gave it a worthy try!

Originally Posted by Taguid View Post
I bought a set of the Ez-Red wrenches off Ebay for the bell housing bolts.
I use this in 3/8". Kinda small for the torque but it's a good wrench. It's become one of my favorite tools as the head is small and the arm is long along with the flex aspect.

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Old 06-09-2016, 01:29 PM
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I definitely wanted to get it off so donating a wrench was s simple choice. Too bad it didn┤t work out as hoped.....

Thanks for the info Bill; I asked my parts supplier this afternoon but he couldn't give me a distinct answer on it. Strangely the cable only costs around 21 euro's, so I'm doubting it will have the bracket on it.

And I just asked a shipping quote through Ebay for a set of EZ-red wrenches....:-)
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Old 06-09-2016, 03:39 PM
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After decades of dealing with stuck fasteners my personal approach is to always use a six point socket, six point wrench or a flare wrench unless I have no choice.

A length of pipe a.k.a. "Torque amplifier" is also essential.
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Old 06-21-2016, 09:50 AM
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I've ordered the EZ-red wrenches, they are shipped....:-)

Luckily the sensor was still available, so with a bit of luck I can still salvage the connector and the damage is minimal.....!



In the meantime we took the transmission to the overhauler, hopefully they'll find no additional damage. Took a while to get it loaded in the back of my car but in the end it worked out very well:





Should be a nice "before and after" picture: she was as dirty as can be....
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Old 06-30-2016, 09:56 AM
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First pics from my transmission on the work bench:








And on top of all the mailman came by with a present:



Will give those upper bell housing bolts another go tomorrow with the new wrench...😊😊😊
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