944Hybrids: 924/944/968 and 928 V8 Conversions
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HOW TO DO AN ADVANCED SEARCH.

Mon Jul 08, 2013 3:56 pm by Admin


For the benefit of 944Hybrids users there are two search functions available for you to use.
The purpose of this sticky is to explain the "Advanced Search" function because it is much more powerful and is the best choice when researching information.

When you log on to the site a list of options is shown in a line at the top of the page. One option is labelled "Search", use this option (NOT the search box lower down on the right).

After you click on the upper search option, a drop down box appears. At the bottom of this box is a radio button marked "Advanced …

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Ray's 1987 944 LS1 Build & Swap

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  matt889 on Sat Mar 16, 2019 11:29 am

what height is ur garage ?

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  Raymond-P on Sat Mar 16, 2019 10:44 pm

Excited to see you're getting your project started. I hope some of my documentation will be helpful. There is so much good info in this forum and most folks are happy to help.

To answer your question, my garage has an 8 ft ceiling, but because of the garage door opener (and the car of course), I can only get the lift to about 9" above the first lock-off spot which gives me 41" under the car. To be safe, I'll be creating an intermediate lock-off spot. The 1st lock-off spot gives me 32" under the car which is not bad.

I too am waiting for the weather to be just a bit warmer so I can keep the garage door open... I need the room to work!
Raymond-P
Raymond-P

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  LStuner on Tue Mar 19, 2019 6:04 am

Kiltacular Jim wrote:Let me tell you, this is an extremely timely return to your project -- I'm placing my order with TPC any day now and picking the engine up next week. Hoping to start tear down once it warms up enough to be in the garage as long as I need to be every evening. Sub'd for sure!


Get ready to wait. (Hopefully not as long as me). I have been waiting 7 weeks for my Manifolds, Fuel Kit, VSS Kit, and Brake Master.

LStuner

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Engine Swap Begins...Finally!!

Post  Raymond-P on Wed Aug 28, 2019 2:33 am

Not sure how 5 months just disappeared, but I have finally made some progress in the engine swap department.  Once I get the pics on my PC I'll begin sharing my engine removal adventure.  Hopefully in a day or so.  Stay tuned.

Below is the engine bay in stock trim...I guess it's my official "before" picture.

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Preparing to Pull the 2.5

Post  Raymond-P on Sat Sep 07, 2019 10:49 pm

With the car in the garage and settled on the MAXJAX, I began the process of removing everything that connected the engine to the chassis or drive train. I photo documented all the parts before disassembling (for posterity), and after a few nights of work, the engine bay was fairly clear on the top side.
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On the bottom side, the exhaust system, starter, hydraulic clutch actuator, and torque tube must come off.

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Breaking the bolts loose was a challenge as expected, but the 24” handle from my floor jack is a great equalizer (torque multiplier).  Some liquid wrench didn’t hurt, especially on the exhaust bolts.

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The stock exhaust system sounds awesome and is for sale.  Contact me if interested.  

Supporting the engine with a lift unloads the torque tube and the cross-member bolts so they can be removed without the engine hitting the floor.  I had to make some adjustments to the lift points.

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Initial placement of the engine hoist revealed some alignment issues...

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Clearly the front bumper needed to come off.  Not a big deal.  Front cowl needed work so I took it off as well.

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Still not exactly the correct alignment but close enough that with a few small tweaks the engine and cross-member will soon be lowered. (Suspect Yes... that's the LS under the purple blanket

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Next post will be the empty engine bay!! Very Happy
Raymond-P
Raymond-P

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Extraction At Last!!

Post  Raymond-P on Fri Sep 13, 2019 11:50 pm

The plan is to drop the engine and cross member out the bottom.  To do this, everything on the top side must be disconnected and there is a lot on a 944S.  The wiring harness is particularly difficult because the support connections are on the back of the engine and can’t be reached while it's in place.

I disconnected the harness from the ECM in the passenger foot well and pulled the connector through the firewall.  I disconnected as many harness support brackets on the engine as I could see and/or reach.  The remainder had to come off later.

Next, I set up the hoist for about 30 inches of drop.  

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I had already removed the steering rack and tie rod ends, and front sway bar, so next was the A-arm ball joints and removal of the A-arm rear mounting bolts (two each side).  

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Then I loosened the cross-member mounting bolts on each side, carefully watching for movement.

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I lowered the engine after the cross-member bolts were just about free, then I checked the torque tube to see how that was going.  Clearly I had a ways to go.

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With the engine and cross-member free, continuing to lower the engine revealed the drive shaft was still holding up the back of the engine.  This condition over rotated the assembly and jammed the distributor into the radiator cavity.  

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After raising the hoist back up to level the engine, a healthy pull forward was enough to clear the drive shaft.  Lowering was a piece of cake after that.  Having a helper would have been nice.

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All set to roll the assembly out from under the car but I needed to raise the MAXJAX about 8 inches more to do it.

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And the 2.5 is officially out (and for sale)!  It does need a new water pump, which is what started this whole adventure.

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Below are the empty engine bay pictures that have been years in the making…

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Lots of miscellaneous parts, hoses, and vacuum lines to remove and lots to clean up!!  Power brake booster coming off soon.  I’m in the market for a Ford Hydro boost and all the “fixins.”

Overall, little to no rust.  Yay!
Raymond-P
Raymond-P

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  smkn951 on Mon Sep 16, 2019 10:17 am

awesome!!
I will be doing the same soon and your journey with this swap will greatly aid in mine.
thank you for documenting this.
BTW...Check out LKQ for hydroboost..I just picked one up used from a 2004 Mustang for $26.00, soon i will be buying the rebuild kit for it, i think it's less than 30.00.
keep the pictures and the adventure coming.
thank you
smkn951
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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  Raymond-P on Sat Dec 07, 2019 11:47 pm

Thanks for the lead on the Hydro boost. I really need to research the swap so I get the right components. Is the 2004 Mustang unit the best fit? I would love a setup where I didn't have to relocate that back coil pack.

I'm also going to replace the torque tube bearings before installing the engine as I'm sure my factory units are shot after 103K miles. They have always been noisy since the day I got the car.
Raymond-P
Raymond-P

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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Torque Tube Rebuild Update - Need Advice

Post  Raymond-P on Wed Jan 01, 2020 10:20 pm

Perhaps a New Year's break!!

So I thought my torque tube had bad bearings because of the noise I remembered during the driving years.  Yes, I bought four new bearings in anticipation of the work and I researched the replacement procedure.

However, upon investigation with the engine removed, the 1st bearing is clearly visible and appears to be in excellent condition.  
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The driveshaft has no run-out, no lateral play, and turns smoothly by hand without noise.  The splines and nub look fine.
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Perhaps the noise I was hearing originated from a faulty throw-out bearing??  

In any case, I'm thinking now that I can move forward without rebuilding the torque tube, especially since the LS will not have the same vibration issues of the 2.5.

As always, consensus from the forum experts means a lot to me and I'm open to the comments/opinions from any willing experienced forum members.  Please let me know if I'm missing something.
Raymond-P
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Post  spence on Thu Jan 02, 2020 3:57 am

When i had my car all apart, i rebuilt the torque tube. Its not bad.
It would be bad, if you got it all back together only to find out you have a unhappy bearing. The bearings may feel fine now, but when they heat up might be a different story.

If you do rebuild it, having the transaxle off the car will also allow to easliy adjust the insertion depth of the tip upon reinstall (critical). Something to think about!
spence
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Post  Raymond-P on Thu Jan 02, 2020 8:31 pm

Thanks Spense, I appreciate your input.

My 083D AGP transaxle will be coming out when I swap it for a 016R 5P transaxle from an '86 Turbo. Not sure of my timetable because I want to do the recommended 5th gear swap first.  Unfortunately getting a 5th gear from an '83-'85 016K QM (or 8Q) is a challenge.  Perhaps one of the 944 used parts dealers here in the US would be willing to swap 5th gears with me for a fee.   That would save wasting an entire transaxle just to get a gear, and several hundred dollars in shipping.  I also have a case reinforcement plate on order from TPC.

Moving forward, I might as well pull the transaxle now just to get a good look at bearing #4.

If #1 and #4 are both in good shape, is it even possible that bearing #2 or #3 could be damaged??  I just don't have any forensic experience with 944 torque tubes to know the failure signs or patterns.

I don't mind doing the work to replace the bearings but it would be nice if I didn't have to. Smile
Raymond-P
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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  spence on Fri Jan 03, 2020 2:47 am

I found my 5th gear brand new old stock on ebay. Keep an eye out on ebay or a forum like pelican parts or renlist. You can even make a want to buy post or want to trade. I think the 5th gear in the turbo transmission is the one the n/a racers want and you can sell it for a good amount.

If your torque tube has 100k miles you should just do the bearings. Your adding twice the power and relying on those 30 year old bearings that you already thought where noisy. Just cause a bearing looks fine from the outside doesn't mean much.
spence
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Ray's 1987 944 LS1 Build & Swap - Page 3 Empty Re: Ray's 1987 944 LS1 Build & Swap

Post  Raymond-P on Fri Jan 03, 2020 9:33 pm

Spence....you are so right!!  Who am I kidding, trying to save a little work...just being lazy I guess.  Embarassed
I'm going back to Plan A and will replace the bearings.

I've seen loose NOS gears on eBay but I do not know the part number I need.  If you can share that with me that would be great!!  I haven't researched this yet but do I need to swap syncros too?

I did a little more checking and the NA 944 transaxles sold in North America that have the 37:27 (0.7297) 5th gear ratio are as follows:
016K QM 944 (1983-1985)
016K 8Q 944 (1983-1985)
016K 5S 944 (1985.5-1988)
016K 7V 944 (1985.5-1988)

Good to know about the 5th gear demand too.  Probably need the correct Porsche PN for it as well.

The gear I will have available after the swap is from the transaxle below:
016R 5P 944 Turbo 1986 With Oil Cooler Standard
5th gear is 35:29 (0.829) Final Drive Ratio 8:27 (3.375)
5P 25026 (Code 5P, Manufactured FEB 25, 1986)  

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I guess I should get the word out now on the gear and the 944S transaxle, even before I make the swap.

The complete transaxle I'll have for sale is as described below:
083D AGP 944 S 1987 No LSD  About 103,000 Miles.  As is.  No known problems or leaks.
1st 10:35 (3.500)
2nd 17:35 (2.059)
3rd 25:35 (1.400)
4th 29:30 (1.034)
5th 35:29 (0.829)
Rev 12:42 (3.500)
FDR 9:35 (3.889)

Thanks again for being the voice of reason in my time of need. Very Happy
Raymond-P
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