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C900 Bulletin Board
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while the dash is apart
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Posted by jp (more from jp) on Sun, 7 Nov 2004 19:19:26 Share Post by Email
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Well, I lost heat in my 88 900t, so with winter coming, I had to fix it. I got the lower dash off, the dash cover off, and the instrument panel off! Quite a chore, and I had to buy an extra long socket extension to get the lower dash off. Visits to Home Depot can get expensive.

I found two vac hoses had come off their actuators. I put one back on. I think the other one went to just above the heater core, which I couldnt easily get to, so I just plugged the hose with a screw. Before I put it back together, I will ziptie the ends so they don't get loose again. I also redid the vac connection to the resoviour in the passenger side front fender. The hose had gotten soft from spilled ps fluid and come off the resovior. Boost was much more predictable after fixing these leaks. This car tends to get lots of vacuum leaks because I run a higher than normal boost. It usually develops a leak again not long after fixing something and getting my boost back. The reason I didn't have heat was the temp control rod had come off - something I could fixed just by removing the radio, but I knew there were many problems needing attention behind the dash.

The next thing I tackled was to remove the clutch pedal and replace it. Someone on TSN had mentioned their clutch pedal had worn out. My clutch had quite a bit of play in it. I could press the pedal 1/3 the way down before it actual operated the clutch. I ordered a new pedal from eeuroparts. I got the old pedal out and it was REALLY worn. The roughly 1/4" hole that pins it to the hydraulics was not round. It was about twice as wide in one direction. That is why there was so much play in the pedal. The new pedal went in pretty easy. One side of the piston it attaches to was worn about 1/8" out of round, but I didn't mess with that. It's not perfect because of that, but it is about 5x better clutch "feel" with the new pedal, and definitely worth the price of a new pedal. If one had a welder, they could refill and redrill the hole as another option. The result is that the clutch pedal travel is much more linear and less on/off.

Question - is the vacuum hose that goes to the brake pedal microswitch (labeled as a #29 in the bentley book) just for cruise control, or does it also function to bleed boost when tapping the brake. I have read that boost is dumped when you brake, but I don't know how it actually does it. Once I understand what this hose is for, I may remove it. The overboost pressure sensor was removed long ago. I don't use cruise control, so are there any other things I can simplify by removing while I'm there?

Next weekend, I'll be making LED lights to replace the illumination in the dash. Then I'll put it mostly back together - at least so I don't have to use wire and tape to hold the instrument panel in place.



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