Bernard IV

I'm also very interested. This should be a fun project.

Capt. Obvious

The 996 all wheel drive is removed now, the 997 unit has been test fit and it bolts right in, though it's a hair larger dimensionally so it takes a little more finessing to get into place. I found my path for the wiring harness from the differential to the controller.

Next on the list is wiring up and mounting the diff controller, rebuilding the axles (the boots are shot), and changing the fluids in the 997 diff and getting it ready for its new home.

There is a glimmer of a chance I might be able to test drive the car with the 997 diff by the end of the weekend?

Capt. Obvious

No test drives this weekend, but I made good progress. I got side-tracked by a couple other little tasks on the car that ate up some time. The wires for the differential controller are run now, I just need to tap them into their respective wires under the dash.

Next up is the axles. Three of the four boots are torn and the fourth probably isn't far behind so I need to reboot the axles. Then I need to clean up the mess left behind from the torn boots.

One of the side projects that ate up a bunch of time this weekend was installing the Function First Shift Right kit. I didn't realize it when I bought it, but it's intended to be used with an OEM shifter. My car has the B&M shifter in it. I like the B&M unit and wanted to keep it, so I had to get creative. I ended up spending well over an hour "machining" the ball on it down to size using a Dremel, file, and sandpaper. It worked!


Here is everything reassembled, and the extra effort to make it go together was totally worth it.


For those of you who have any of the 996/997 factory shifters in your car but wish there was a little (or a lot) less free play in them, YOU NEED THIS. This is one of those mods where as soon as I was done reinstalling everything and tested it I thought to myself "I should have bought this a long time ago and installed it the second I received it!" One of the reasons I put off purchasing it was I felt it was a bit expensive for what it is. However, after seeing and handling it there is actually quite a bit of engineering and machining involved in this unit and I appreciate the price much more now. For comparison, the shift action is damn close to that of the Numeric shifter, but for less than half the price.

Dock

That's nice work.

Capt. Obvious

Oh, and I have two questions for the wiring diagram gurus out there:

1. I can't find a pin-out diagram for the throttle pedal. I know there are two 0-5v signals that are sent from it. Best I can tell it is pins 5 and 6 on the connector, with one signal controlling the "open" and one controlling the "close" function on the throttle body. I need the open signal, or does it not matter (I would assume the close signal would be the inverse of the open signal)?

2. Is there a 5v power source available that is safe to tap into? The 997 diff has a temperature sensor in it and I'd like to send that signal to my diff controller to set the diff to 0% when a certain temp threshold is passed.

theprf

Here's a clip from the wiring diagram.
Most egas pedals have two pots working in opposite directions: push the pedal down and one pot reduces value while the other increases value.

Do you need 5V to power up the sensor in the diff or do you have something different in mind?

k9turbo

great mod on that b&m - agreed. wish list stuff.

Capt. Obvious

Thank you, that was exactly the diagram I was trying to find (I could only find diagrams for the connector on the throttle body). Looks like #6 is my wire.

And correct, I need the 5v to power the sensor. I could just use something like an L7805 voltage regulator to drop it to 5v, but I would prefer to use an existing source if possible.

Capt. Obvious

No one knows of a 5V source under the dash?

theprf

You should be able to get +5V from the gas pedal. It comes in on the green/black wire (A3).

Bernard IV

I used this on my secondary MAP sensor for my fuel pump. Working well.

Capt. Obvious

Good news: the 997.2 diff is in and operational! I still have the car up in the air to finish up some other things so I haven't road tested it yet, but it works as expected when I toggle the differential controller.

Of course, before I could do that, I had to go through the misery of rebuilding the axles since 3 of the four boots were split. Rebuilding axles is easily in my top three most hated automotive maintenance/repair things to do, but sometimes you just have to do what you have to do. As is par for the course when I do these things, the first one took over an hour to put back together and the second one took took minutes. Story of my life.


Shiny new boots.


Here is the 997.2 (left) and my dirty original diff on the right (looks like I had a weeping flange seal plus gunk from the torn boots). As you can see they are more or less dimensionally identical. You have to swap the mounts from the 996 diff to the 997 diff, but other than that the mechanical side of things is plug and play for this. You reuse the 996 cardan shaft.


Here is the diff in its home before I finished up the wiring and routed the breather tube. I didn't take many pictures of this part of the process because I'm working with the car on Quick Jacks, so it's only 18" in the air and frankly, there isn't much to see here anyway.


All wired up and ready to go.

Capt. Obvious

While I was under the car I also replaced the original transmission mount, which as expected was totally shot.

I also added some additional 997 bling under the car while I was at it.


While not a particularly difficult thing to install, it is deceptively more work than it appears to be since a few things need to be moved out of the way.


Next up on the list is a new clutch master, AC condensers, and windshield washer pump then I can put it back down on the ground for a test drive.

2fcknfst

I have that exact same Sony Ipod radio thing.

Looks very good, you should install some intercoolers too...

Driving impressions are what I am looking forward to.

Carlo_Carrera

Good work.