When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
Acetone mixed 50/50 with dex IId (non-synthetic atf) applied liberally works on stubborn stuff. It's a good idea to tap fasteners with a light hammer and light touch.
There is no need to disassemble the accessory belt drive assembly.
Jimmy, Welcome.....Im not to far south of you in Alexandria and have been wrenching on 968s for a few years, have a few tools and some spares that may help. Saw your 996 sway bar post on Dorkiphus.....Had 3 of the local 968s at a cars and coffee last weekend. May try again to get a few local 968s out, there is a cars and coffee at The Haven restaurant just south of Old Town this Saturday AM
Thanks John - would love to learn from someone local … I didn’t know about the Cars & Coffee at the Haven although I’m a semi-regular at Katie’s and, pre-pandemic, at Crooked Run. My 968 is going to be on stands for another week or three, but depending on timing I could join you on Saturday in the S4?
I was thinking (dangerous)…. Since you have the skills and determination, would you consider pulling the motor out? It makes the engine-related work so much easier and you’d feel good that you were able to inspect for all leaks, etc. I did it in my driveway with just hand tools and an engine hoist. You’d have to be very mindful of scope creep though! Just a thought…
Well, the offending bolt is out, the new belts are on, and I should get the timing covers buttoned up tomorrow. Then it’ll be on to steering leaks.
sm, I see where you’re coming from - although the last engine I removed was from my first car, a 1974 VW Beetle, nearly 30 years ago …
For this 968, though, I want to get it to ‘driver’ condition first so I can have some fun with it, get to know it a little and figure out what’s next. I’m already susceptible to scope creep, as testified by the multitude of power steering components that UPS, FedEx et al are currently bringing to my house on a daily basis - I fear if I took the engine out of the 968 I’d be knee deep in some kind of mad scheme before you could say “turbo 07K transplant” (which, incidentally, is what I had planned for my beloved 4000 Quattro a few years back before it met with an unfortunate accident one rainy afternoon)
I see where you’re coming from - although the last engine I removed was from my first car, a 1974 VW Beetle, nearly 30 years ago …
I had a 1962 VW. Back in the day the engine could be dropped in about 15-30 min as it was just undue the throttle cable and remove 4 bolts. It's first upgrade was a 356A engine I pulled from a rusty old tub. After that it got a 1500 GS Carrera 4-cam transplant... damn, wish I still had that engine! I'm enjoying reading about your project.
Ha, I wish I’d been able to do that with mine - I only went as far as a mild Weber-carbed 1600.
No cars and coffee for me this morning (sorry @jsheiry ) - I decided to get into the steering system instead while I wait for the few parts I need to button up the timing belt side of things. Honestly, it looks like every place that could possibly be leaking steering fluid is doing exactly that. Plus the PPI had suggested metal flakes in the reservoir, so I figured let’s just replace pretty much everything. Only had a couple of hours before rain stopped play, but here are today’s victims:
Also removed the oil cooler lines to better get at the steering hoses. The PPI had reported the oil lines were leaking, but it looks like they were just coated in steering fluid / ATF, not actually leaking motor oil.
Hoping for better weather tomorrow to get the rack out …
if you rebuild the power steering pump, it is wise to replace the circlip as they typically deform walking them off. Merc sells it as an individual part.
There is a non-replaceable filter in the reservoir housing.
Most rubber bits are toast after 18-20 years with or without ATF exposure.....rack mounts, rack bellows and castor blocks should be inspected/replaced while it is under the knife.
After much contortion I got the rack out today, along with the return line. I think I’m at the stage, at least for this initial chunk of work, where there’s nothing else to remove; all that remains is to put things back together.
Hadn’t realised the ‘early’ steering reservoirs were sought after; I’ve saved it from the trash and it’s already spoken for. Hopefully it can bring joy and authenticity to someone and their car … since there were no 1992 ClubSports, I guess the replacement reservoir is perhaps more appropriate for the “tribute” I think I’m building?
Obligatory pic - the old and the new (or at least remanufactured):
Take a close look at the reservoir. If it doesn't leak, you should consider retaining it. Those clear top units are not common...
I bought a new one when I fixed my PS a couple of months ago but I couldn’t bring myself to replace the perfect original.
They say the filter is non-serviceable but 3x soak and swish with Wurth Brake/Parts Cleaner flushed backwards had it coming out as clean as it went in.
11-09-2021, 08:10 PM
(which, incidentally, is what I had planned for my beloved 4000 Quattro a few years back before it met with an unfortunate accident one rainy afternoon)
