Bruised And Battered Knuckles What Would You Redesign??

[944Scott]

With all the problems I've had in the past few weeks I have had plenty of time laying under the car using expletives to help pass the time whilst I ponder what the designers were thinking as the car evolved from the sketch pad. A decade ago I would have retreated to my garage perch with a cigarette to focus the mind as I figured out a solution but those days are long behind me but its still the cigarette I miss the most. So my question to you guys is if you could, what bits would you re work for ease of maintenance?

Two easy ones for me.

Torque tube

I'd make the gearbox bell housing two piece to allow it to be completely removed in the break down of the torque tube thus allowing the tube to slide out without having to drop the suspension.

Reference Sensor Bracket

Why on earth would you design the set up in such a way as you cannot remove the bell housing with the sensors in place? surely (no it is) easier to set them up in situ with the bell housing removed.

 

[zcacogp]

I'd start with that daft oil filter that drains itself over the nether regions of the engine whenever you remove it and which you can't pre-fill when fitting a new one.

And move on to those calipers with dissimilar metals in contact leading swiftly to galvanic corrosion.

And what about the rubber rear spoilers with the water drain holes that are precisely the right size to block with any passing leaf, sycamore helicopter, seed pod or similar that happens to be passing?

Oh and the rust-traps that the turbo/S2 lower wing trims on the front. Actually, let's put the whole of the sill trims into this category 'cos they all do the same.

And the rear suspension torsion bar that is a major operation to remove.

And the clutch that requires removal of every part of the drivechain downstream of the flywheel when replacing it. Systeme Panhard and all that bollox, and it shows ....

I'd make the gearbox bell housing two piece to allow it to be completely removed in the break down of the torque tube thus allowing the tube to slide out without having to drop the suspension.

Do you mean you need to drop the rear suspension to get the torque tube out? []

Oli.

 

[blade7]

Water pump that can be accessed easily. Fuel filter in engine bay. 944 Clutch access through bellhousing (968).

 

[944Scott]

Correct and now it is stuck like this until I can get the reference sensor bracket off and the clutch in

 

[blade7]

That's an impressive axle stand collection...

 

[vitesse]

I cut through the bracket on my red 924S using an Eclipse pad saw & fitted another S/H one when I replaced the sensors ( all in a past post)

I am told that competition people have resorted to cutting away the bellhousing casting metal to form a slot so that the housing slides away leaving the sensors/bracket in place.

 

[944Scott]

I am considering cutting it off and I spotted a new bracket has been redesigned.

 

[944Turbo]

My bellhousing is cut on the coupe to make removal easier on a revisit, Also I think on a ramp if you rotate the torque tube 180 degrees it will come out over the axle - not sure about on stands,

Tony

 

[PAUL RUDDY]

I would rather do a clutch change with mole grips on my testicles than remove central locking door handles ever again....

Guess what I am doing at the moment, and it doesn't involve mole grips !

 

[scam75]

My car is getting a full respray just now and the painter was decrying the removal of the door handles and seems not overjoyed at the prospect of refitting them! Funnily enough I had one non script handle, passenger side, which I replaced with a script one, and don't recall there being too much drama once the metal cover plate was removed and window runner unbolted from the bottom. Getting purchase to pop the ball joint back on I seem to recall was fiddly. I also recall Alastair (Sulzeruk) on here once showing me how to complete this operation from the outside, without even removing the door card! This was beyond me unfortunately!

Stuart

 

[robdimond]

Door handle is like keyhole surgery... I have always resorted to taking the door card out, window out, window runner out and then it's very easy. Often the fastest way involves the most disassembly. Can I put a mention in for the windscreen and headlight washer reservoir? Also the S2/Turbo oil cooler hoses.

 

[jellytott]

Add to that engine mounts

 

[944Scott]

I'm yet to tackle engine mounts

 

[jellytott]

I'll await your reply Scott

 

[edh]

I agree on the engine mounts

I did one on my turbo - after advice from my indie...... never again!

I think it's lot easier for a home mechanic to remove the crossmember entirely when doing this job TBH

 

[Frenchy]

I hate trying to refit the distributor cap, door handles don't go there !

I have not done them but a mate who is handy said that the rear wheel bearings were a monster, torqued up to a million pounds square

Agreed oil filter is a stupid bloody idea, oil pressure sender sensor is another sod to do, I have a cut down spanner in the chest now.

Turbo to down pipe bolts WILL shear if you come to remove them, another world of pain, the crush ring will also,see many hours of grief to remove.

There are others !