996.2

We have a Mk2 and most postings and even Porsche's Illustrated Parts Manual show a Mk1 which mounts from the side instead of top and has the bellows. In all the material I reviewed I didn't learn there is ONE MORE HOSE AND CLAMP UNDER Mk2 AOS, and now understand why we were advised to get the remote operating hose clamp pliers. Apparently those are mandatory to get the clamp off the bottom of a Mk2 where the engine was not completely taken out, at least with a Tip transmission.

It would be nice if the Rennvision video would show the significant differences between Mk1 and 2 and Tip and manual trans, use of the mandatory remote hose clamp pliers, and tips to make any future disassembly much easier such as installing hex allen socket head bolts on the 6th position and AOS mounts (where a very thin ball allen wrench can slip right down to them).

silver9962002

How big of a deal would it be to cut a hole? sounds like a good idea, what else is in the way?

Porschetech3

You think I should include a " Trap Door Kit" with each UAOS? Ain't gonna happen cap'n !!

Just suck it up buttercup, get your hands dirty,knuckles bleeding !!

silver9962002

Ski pass through.

Just include a cut off wheel and template.

Porschetech3

lol,,, Nope, not gonna entertain cutting easy access on a Porsche of any year., it's not really that bad of a job.
I use to feel guilty charging 3 hours to do an AOS on 996.1 6MT , because I could do it in 1 hour , and there is no book time to judge by..

If it were a 20 year old Dodge Ram maybe..

996.2

6th manifold bolt is difficult to access because socket is about .550" diameter and gets trapped between AOS diaphragm and manifold. Purchased new socket head bolts for reinstalling manifold and AOS, driven by slim .225" dia ball end hex tool with the short arm cut off. This will make reassembly and future removals relatively easy. Ball driver should be strong enough to apply 7.5 ft/lbs of torque, and allow tilting to access when bolt head is shielded.

I have stainless steel and zinc plated socket head bolts, they will be mounted in aluminum and will dissimilar metals have a galvanic reaction? I think yes, and the zinc coated would have less reaction so we should use those?

Porschetech3

Nice Tip/Trick, thanks for posting.

Couldn't source any Brass Allen head bolts I suppose?

nrp3

Wouldn’t the use of copper or zinc anti seize on the threads pretty much negate the need for stainless fasteners? The Allen head bolts sound like a great idea though.

De Jeeper

Go zink, stainless and aluminum dont play well together.

996.2

The bolt supplier's website had stainless, zinc coated, and black oxide, and I didn't think to search for brass or other materials.


I've got zinc coated on order so will use them for the 6th manifold and AOS bolts. They're only 39 cents each https://www.belmetric.com/6mm-yellow...c-p-14361.html .

moosetaco

I think Porschetech maybe eluding to how easy that bolt will be to strip, especially using a ball end driver. I would strongly suggest using a non ball Allen driver to install and remove that bolt if you switch over to it. Good luck 🍀 🤞

Porschetech3

Here ya go !! ,,High visibility, non-corrosive to aluminum.. "bitch bolt replacement" significant weight savings also.....

996.2

My Daddy got frustrated so I got it. What cleaner should I used to get oil off hoses and engine?

TexSquirrel

Cute!

I use Simple Green.

Porschetech3

If she completes that AOS installation for you, I got a job for her, she will be my new UAOS spokes-person !!!! LMAOO