Go Big or Go Home: Clay's 914-6, MS3Pro Wiring in Progress Options

[ClayPerrine]

I fixed the pedals...





I turned around the shaft, straightened up the arm, and shortened it so it wouldn't hit the pedal arm. New pin made from solid steel, not a spiral pin. Heated both ends with the torch and flattened them so it won't come out.

The right end had the tube in the pedal base shortened and the bushing reinstalled. Then I put a washer and cotter key in to make sure it doesn't come out.

Now to see what's wrong in the transmission...





Opened it up and found nothing wrong. With the cables disconnected, it shifts fine through all the gears. (IMG:style_emoticons/default/confused24.gif)

Hooked up the cables and shifted it to first at the trans. The shifter was in first. Pulled the shifter to second, and the trans won't engage second gear. At the trans, I am able to put it into second. So now I think there is a problem with the shfiter.

I am going to put the trans back together after lunch and pull the shifter to see what is wrong.

(IMG:style_emoticons/default/smash.gif)

But at least I know what it looks like inside now. (IMG:style_emoticons/default/biggrin.gif)

[Rob-O]

But at least I know what it looks like inside now. (IMG:style_emoticons/default/biggrin.gif)

Yeah, clean! Glad to hear it’s in the shifter and not the box.

[ClayPerrine]

So I found the problem.....



This is the bracket that is supposed to hold the shift cable in the tunnel. It was made from part of the Toyota shifter, and I kinda under-engineered it for my use.

So tomorrow I make a new cable mount.

[Rob-O]

I’m not sure exactly what that looked like when it was tabbed up. But it looks pretty beat up now.

I’m sure it’s a bit frustrating. But if you think about it, if this is your only issue after this build I’d say this is minor.

[ClayPerrine]

I’m not sure exactly what that looked like when it was tabbed up. But it looks pretty beat up now.

I’m sure it’s a bit frustrating. But if you think about it, if this is your only issue after this build I’d say this is minor.

The bent parts were a flat ring with a notch cut in it. The new one is going to me made a LOT stouter to accommodate my "aggressive" shifting style.

And that is not the only issue. I have a leaking timing box cover. I suspect it is warped. The timing boxes and covers are magnesium, and are really prone to warping and leaking. I am going to try to tighten it up.

[wvspin2]

First of all, I am glad you had a safe trip to pick up your suv (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/smash.gif) .
Secondly, you really dodged a bullet (IMG:style_emoticons/default/ar15.gif) finding a pin in the peddle box and adapter in the tunnel box. You certainly deserved a good break after all you went through coming home from NC. I was so glad you had all the joy of making the drive at Okteenerfest with your 4.0 mod machine. (IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/driving.gif) It's a wonderful machine. Looks like you'll have it back running soon. (IMG:style_emoticons/default/beerchug.gif)

[ClayPerrine]

Looks like you'll have it back running soon.

Tomorrow...... It will be running tomorrow.

[JFJ914]

And that is not the only issue. I have a leaking timing box cover. I suspect it is warped. The timing boxes and covers are magnesium, and are really prone to warping and leaking. I am going to try to tighten it up.

Ah, yes all 964's leak there. Mine did

[ClayPerrine]

So I got the cable mount for the shifter fixed. Got everything buttoned up and tried to back out of the garage. The clutch works great, but I got the shifter mis-adjusted.

I also don't have an oil pressure idiot light. I can see oil pressure on the gauge, but no light.


Oh well... As Scarlet O'Hara said "I'll think about that tomorrow. After all, tomorrow is another day."

[Dr Evil]

I fixed the pedals...

I turned around the shaft, straightened up the arm, and shortened it so it wouldn't hit the pedal arm. New pin made from solid steel, not a spiral pin. Heated both ends with the torch and flattened them so it won't come out.

The right end had the tube in the pedal base shortened and the bushing reinstalled. Then I put a washer and cotter key in to make sure it doesn't come out.

Now to see what's wrong in the transmission...

Opened it up and found nothing wrong. With the cables disconnected, it shifts fine through all the gears. (IMG:style_emoticons/default/confused24.gif)

Hooked up the cables and shifted it to first at the trans. The shifter was in first. Pulled the shifter to second, and the trans won't engage second gear. At the trans, I am able to put it into second. So now I think there is a problem with the shfiter.

I am going to put the trans back together after lunch and pull the shifter to see what is wrong.

(IMG:style_emoticons/default/smash.gif)

But at least I know what it looks like inside now. (IMG:style_emoticons/default/biggrin.gif)

Those picks make me feel funny in a good way (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/biggrin.gif)

[ClayPerrine]

So this evening I fixed the oil light. Broken wire in the 14 pin plug to the relay board.

Fixed the shifter, and still didn't have reverse. (IMG:style_emoticons/default/headbang.gif) Got online and searched the 987 forums on Pelican and Rennlist. Found lots of posts about no reverse gear that said to adjust the shift linkage. Considering that I am not running a Cayman shifter, I wasn't able to use the procedures they outlined. But I was able to disconnect the cable at the transmission, then put it in reverse by moving the input shaft. I know it was working because the backup lights came on. I adjusted the cable on the transmission end so it would hook up correctly.

TA-DA!!! Now I have reverse. I start the car up, and back it out of the garage. I put it in first and start to pull away down the driveway, and it dies.

I don't hear the fuel pump running. The cheap aftermarket replacement 964 pump died. I have power and ground to it. I tried tapping it with a hammer. Nothing.

(IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif)

What the H3LL do I have to do to catch a break???? The tank is completely full of premium unleaded. So now I have to drain the tank to replace the cheap pump with a real Bosch pump that I should have bought in the first place. (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif)

Off to email Aaron@allzim.com to order a 964 factory pump.

[ClayPerrine]

Those picks make me feel funny in a good way (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/biggrin.gif)

So... are you going to start rebuilding Cayman transmissions now??? (IMG:style_emoticons/default/poke.gif)

[Jamie]

So this evening I fixed the oil light. Broken wire in the 14 pin plug to the relay board.

Fixed the shifter, and still didn't have reverse. (IMG:style_emoticons/default/headbang.gif) Got online and searched the 987 forums on Pelican and Rennlist. Found lots of posts about no reverse gear that said to adjust the shift linkage. Considering that I am not running a Cayman shifter, I wasn't able to use the procedures they outlined. But I was able to disconnect the cable at the transmission, then put it in reverse by moving the input shaft. I know it was working because the backup lights came on. I adjusted the cable on the transmission end so it would hook up correctly.

TA-DA!!! Now I have reverse. I start the car up, and back it out of the garage. I put it in first and start to pull away down the driveway, and it dies.

I don't hear the fuel pump running. The cheap aftermarket replacement 964 pump died. I have power and ground to it. I tried tapping it with a hammer. Nothing.

(IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif)

What the H3LL do I have to do to catch a break???? The tank is completely full of premium unleaded. So now I have to drain the tank to replace the cheap pump with a real Bosch pump that I should have bought in the first place. (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif)

Off to email Aaron@allzim.com to order a 964 factory pump.

Why don't you just put a clamp on the fuel line out of the tank, saves a lot of fuel draining except for the rest of the fuel system? (IMG:style_emoticons/default/huh.gif)

[ClayPerrine]

So this evening I fixed the oil light. Broken wire in the 14 pin plug to the relay board.

Fixed the shifter, and still didn't have reverse. (IMG:style_emoticons/default/headbang.gif) Got online and searched the 987 forums on Pelican and Rennlist. Found lots of posts about no reverse gear that said to adjust the shift linkage. Considering that I am not running a Cayman shifter, I wasn't able to use the procedures they outlined. But I was able to disconnect the cable at the transmission, then put it in reverse by moving the input shaft. I know it was working because the backup lights came on. I adjusted the cable on the transmission end so it would hook up correctly.

TA-DA!!! Now I have reverse. I start the car up, and back it out of the garage. I put it in first and start to pull away down the driveway, and it dies.

I don't hear the fuel pump running. The cheap aftermarket replacement 964 pump died. I have power and ground to it. I tried tapping it with a hammer. Nothing.

(IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif)

What the H3LL do I have to do to catch a break???? The tank is completely full of premium unleaded. So now I have to drain the tank to replace the cheap pump with a real Bosch pump that I should have bought in the first place. (IMG:style_emoticons/default/headbang.gif) (IMG:style_emoticons/default/headbang.gif)

Off to email Aaron@allzim.com to order a 964 factory pump.

Why don't you just put a clamp on the fuel line out of the tank, saves a lot of fuel draining except for the rest of the fuel system? (IMG:style_emoticons/default/huh.gif)

The fuel pump is under the tank. I have to take the tank out of the chassis to replace the pump. Gasoline weighs 6lbs /gallon, so that is almost 100LBS to pull out of that hole.

[914forme]

(IMG:style_emoticons/default/agree.gif) And that is why I got a 75-76 cover to build a pump mount in the earlier chassis. You can also mount it to the steering rack, and just have to pull a dust shield. Done it both ways. I hate having to pull a tank to get to a fuel pump.

Cut a hole in the floor of an Astro Van once so I did not have to drop the tank for a third time. Crappy GM design

[ClayPerrine]

(IMG:style_emoticons/default/agree.gif) And that is why I got a 75-76 cover to build a pump mount in the earlier chassis. You can also mount it to the steering rack, and just have to pull a dust shield. Done it both ways. I hate having to pull a tank to get to a fuel pump.

Cut a hole in the floor of an Astro Van once so I did not have to drop the tank for a third time. Crappy GM design

I have a 75 fuel pump mount cover in my parts stash. It's missing the actual mount. I used it for the 964 fuel filter in the engine compartment. (IMG:style_emoticons/default/biggrin.gif)

[ClayPerrine]

Today I drove it to work. I lost the gauges when I hit a bump coming into the airport. Drove the last 1/2 mile in with all the gauges pegged at the bottom.

Lunch will be spent troubleshooting the gauge power issue. I suspect a blown fuse.

[db9146]

[76-914]

Your presently in the "debug" chapter of this conversion which only has 2 emotions. (IMG:style_emoticons/default/piratenanner.gif) or (IMG:style_emoticons/default/headbang.gif) Either way, enjoy the Hell out of it.

[ClayPerrine]

Fixed the fuse at lunch. Gauges are working again. I have a broken instrument light wire in the speedo. It is broken right at the socket, so I need to scavenge one off a junk harness and splice it in.

The biggest problem is it has a huge tip-in problem. When warm, it will die trying to accelerate from a stop. It even happens with the car idling at 1500 rpm. I now know that the used throttle switches have an intermittent open in the common wire. That will cause it. Hopefully I get the new throttle switch assembly tomorrow. I want to take it to the AX on Sunday.

I also let Aaron@allzim.com (on here as partsguy22) drive it. He is the machinist on this project, and he has a lot of time invested in it. He is a Miata guy, and had never driven a 914. This was a hell of an introduction to them. He says "It needs bigger brakes, and more tire on the back".

After moving the throttle switch wires, I got to drive it home with no check engine light. It drives really nice... pulls smooth and drops to idle with no hunting or surging.

I like DME! (IMG:style_emoticons/default/biggrin.gif)