944 Rear Torsion bar dismantle question F/U

[LOAF]

Hey Gents,

I finally got around to working on the Vert.. Had to take some time off, as my focus wandered and shifted to the WRX.. She is doing well, and has provided me with some valuable track time at Summit this year, and later in July at Watkins Glenn.. With the price of 94 going up every day I need to refocus and get this car on the road.. So I need to ask the question one more time. I feel it can't hurt to ask as I have gotten mixed answers.. and the fact that the Porsche shop charges around 80 an hr for labor..

Enclosed are pics of the 87+ torsion bar assembly without the Alumn Arms and Brakes. What I am trying to determine is whether the Spring Plates can come off without killing me.. I know another fella, did this and admitted it wasn't the smartest.. he got away with no problem.. but I am not sure I want to take that chance...

As usual, any help appreciated.. and if anyone has some 225/45/17 for my WRX's Prodrive P7 let me know For now they are acting as stools

Take care
Alex

[boygenius]

This is what I did with my car when I had no body on the chassis to hold it down. I took a floor jack and placed the cup of the jack under the bottom of the spring plate. I than wrapped a chain under the jacks front wheels and used a bolt to secure it to the shock tower. Just put a little preload on the spring plate and use two large screw drivers to wiggle the the spring plate past its stop and than slowly let the jack down. Hope that helped.

[Steve C]

Hi

Just get some threaded rod, make an end to fit in the end of the spring plate and the other to bolt onto the mounting boss above the spring plate, then just lever the spring plate of its stop and let it down slowly.

1302Steve

[LOAF]

BoyG and Steve Thanks..

Steve is there a way you can maybe draw on my pictures to show exact mounting locations..

If not I will see what you mean when I dismantle the one on the car first..or send it out to porsche..

I just can't seem to get this..

Anyone in the Tri-state that would be willing to help..

I could come to you

Alex

[Steve C]

Hi

Do you have a larger picture of the 1st picture that I can draw on?

Steve C

[LOAF]

Sure,
I will check your User account for an email address and send or will try to post..

THanks
Alex

[LOAF]

Steve C thanks for your help..

To all, finally after much research I was able to remove the spring plates and torsion bars off the 87 944 torsion tube housing, which was off the car and in the basement.

To recap, what I have learned..

Safety First- With the torsion bar housing off the car, you can not utilize the traditional ways to dismantle this assembly. I did a lot of research on this since I did not want to hurt myself. What I have learned by reading posts on 911 and 944's is that their is a lot less preload on the 944 87 spring plates. For these cars what is typically done is to use strap to hold in place the alum. arm and brakes so that when you remove the bolts on the spring plate cover the weight of the brake assembly and wheels don't cause the arm to come crashing down. This was repeatedly stated in multiple sites. There was never any mention of preload, which confused me, since the VW folks have always stated as having this. I have yet to do the Vert, but will utilize the proper tools for this to simplify.

Tools- Having realized that there would be little to no preload I proceeded to dismantle the assembly. First by loosing 3 of 4 of the Spring Plate cover bolts and then the last bolt which has a bushing that acts as a stopper for the spring plate. At first I was going to utilize a threaded rod and jimmy rig something but since I am no structural engineer I did not want to take a chance and utilize a weak tensil strength rod that would snap under load. I would have put more effort into this but I ultimately would have been cheaper and safer to buy the right tool. Lesson learned.. Unless you have the time and can use some engineering to actually figure out what grade and tensil stregnth steel to use..

When I removed the stopper bolt, the spring plate did move. I would say between 1/8 and 1/4 inch. This is not much but it is still enough, and you need to realize that there will be some movement. Wear your safety goggles as you never now what can happen.

The rest of the dismantling is pretty straight forward. You may need to utilize a hammer and pry bar to get everything loose. With a little elbow grease it will come off.

The 944 assembly has a lot of extra bolts on the plate for adjustment.. I think camber and ride height. I did not make any markings on the assembly to indicate starting points and ending points for the arms as these markings would not carry over to the vert. I will have to source a protractor and make a best guess on the install, and most likely have a professional set up the cars alignment, ride height, camber and corner balance.

Now I am faced with the issue of removing the old rubber so that I can put some beetle bushings and transfer to the vert. If anyone has any suggestion feel free.. I know it has been mentioned so I will do a little searching. Not sure what will transfer besides the torsion bars, spring plates, and alum arms. How about the 944 spring plates, but I guess that would imply utilizing a 944 bushing. Will research as it has been mentioned.. I think Zen may have.

Still have some work to do on rebuilding the rear calipers, putting fresh pads and new rotors.. $$$$ Still have to figure out the swaybar install and parking brake. Again all researchable topics..

I am happy that I have made progress on this and no injuries. If anyone want pictures or more detail feel free. I will not be transfering anyything for a little while since I need some new bushings and all the above to do prior.

To all thanks for the help, and I will keep everyone posted.. Couldn't have done it with out the Team "Germanlook.com". And I am always grateful for any and all help..

Alex
"Loaf"

[boygenius]

You can cut off the extra attachmect points of the 944 end caps and use them with the 944 outer bushing. I used a sawzall to remove large chunks of the inner bushing and finished it off with a wire wheel in an electric drill. Than just use the VW inner bushing. You will need to use longer hardware if you use the 944 end caps though.

[LOAF]

Sounds good, I will look at when I get home from work..

Thanks..
alex

[boygenius]

Here are a few pics of my 944 rear suspension setup. I have more pictures if you want to see more. Hope they help...

[LOAF]

B,

Million dollar question for you.. and to anyone else that has insight..

Why go 944 Spring Plate covers?

It seems that it is a lot of work.. To cut the excess off.. Use 944 bushings on the outside, and deal with possible bolt clearance issues.. Can some you elaborate as to the need.. Is it because they are beefier..

I already got some beetle bushing but now I have to debate if it is worth calling pelican for some parts.

Please help.

Alex

[boygenius]

Cutting the extra mounting points off takes less time time than trying to remove the 944 outer bushing. I used them since they are stronger than the stock covers. You can just remove the 944 outer bushings and replace them with beetle bushings and use your stock torsion end caps.

[LOAF]

Yeah this seems like a PITA..

Either way I think I would want to remove the old outer bushing and replace it... Not to sure how how many miles were on the car before it arrived in my hands..

So let me car...

If I use stock 944 outer bushing, then I use stock 944 spring plate cover, just modified like in your pics.

If I use the beetle outer bushing, then I can use the beetle cover, with no modification.

Either way I will struggle with the outer bushing..

Torch and saw seems to be the best approach to removing them. Any other tricks.. I remember reading a few posts on the subject.. but am confused as to which one.. I will also research again..

Thanks
Alex

[LOAF]

BG,

Went to the basement yesterday and started thinking about using the 944 springplate covers.. I don't have access to a bandsaw.. What did you use to cut the extra parts off.. Do you think it is possible with a hacksaw..

You having cut them off already, is the metal quite hard..

What kind of shop would have a bandsaw to chop it off.. or do you think a vice and a sawsall-(sp) will work.. I need to pick one of those up anyway for the floor boards..

ALex

[boygenius]

I just used a sawzall to cut off the extra metal. If you are going to use a hack saw get ready for a work out... But it could be done... Rememder to use some spray lube when cutting to keep the blade cool and it will last longer.