So after the unscheduled repair to the 944 I have got my time back for the work on the 996 once again, previous and new lists below.
infrasilver said:
to be done in Red
Brake pipe O/S front
Caliper bleed nipple extraction
Front caliper seal kit.
Brake bleeding, again.
Clutch bleeding, again.
Creaky clutch slave cylinder.
Added to the list January,
New slave cylinder
New release bearing
N/S steering arm, inner and outer
Added to the list April,
Targa roof leak, same place as last time.
Rear caliper seal kit.
Low tone horn
N/S headlight intermittent fault (plug).
Waxoyl inner sills.
Smoke test EVAP system for leaks.
I started off with the front N/S corner as there are a few things that need addressing here, most pressing is the broken bleed nipple. It has been like this for a few years now and I have had a few goes at getting it out including easy out and welding a nut on but both times it has failed. I had been bleeding the brakes through the fluid connection on the side and the other bleed nipple.
I started off by removing the caliper but both the hard lines ends were quite stiff and to save breaking anything I cut the line and crimped the end over to stop any fluid loss while the caliper is away.
It was easier to tap a socket onto the calipers end and remove, this saves any further issues with this caliper.
As you can see it has had some heavy work in this area trying to remove the nipple in the past, heat, drill, left hand drill, easy out and welding. I have been in touch with Thomas of Pro-calipers and he is going to have a go at it for me.
Both front calipers will get repainted and new seal kits are being fitted before refitting. I also ordered Titanium ends for the hard line as I'm sick of these also seizing.
I wanted to remove the pistons before I sent the caliper off so I had to come up with a way of doing this without compressed air as I am away with work and don't have my compressor handy
I though what I could make to allow the calipers to be lifted out. The best I could think of was compressing rubber grommets into the piston recess and hoping this would be a strong enough bond to lift them out. I impressed myself as they came out without too much of a problem at all.
I thought I would post pictures so it can be copied if required.
Just use a couple of rubber grommets that are a decent fit into the piston and using a bolt and two washers that are also able to fit into the recess, tighten the nut to create a tight fit. Fit the larger washer and nut above and just get both hands and using fingers over the caliper, lift the pistons out.
I only found one piston bore with a little crud in it, in the top of the picture.
The caliper will be with Thomas for the next few days so I will be getting on with the horn and headlight plug while also starting to remove the rear of the arch liner to check for potential rust in the inner sills.