My new 944 ... and it's issues

[PSU_Crash]

More fun with the 944
I finally found the security system brains. Under the dash with a screw into the driver's vent duct holding it. Followed wires back to find it tucked way up in there.


I had a power steering leak that I thought was coming from the resevior to pump line. Ordered a new moled line and grabbed a few feet of 3/8 line to do the other side. I can't believe it didn't leak worse! This was the line from the cooling loop. Cut the crimp at the cooler and put a line right on the barb. Good to go now.


While hunting for the security system I pulled the pass side footwell. I'm pretty sure this "floor board" is not factory


Trying to get the hatch to work I took off the rear headliner piece for hinge access. It was kind of falling off anyways ... now I know why. Binder clips, plywood and glue. Excellent. That's garbage


After cleaning and testing the AFM to try and correct the off idle stumble I decided to reset the TPS switch and make sure that was working. It is. What's odd is that if I turn the throttle stop just enough to come off the idle switch it runs much better. Revs clean off idle and doesn't drop way low before recovering after letting off. That seems the oppsosite of what should happen, right ??

Still trying to hunt down the no wipers or radio issue. Fuses check good and I have the cowel off. Time to grab the schematics and meter. That's today's project. Maybe start on the shift linkage too. I also attempted to get the old O2 removed without any luck. More PB and heat again today. I'm pretty sure it's original and it's on there!

[blueline]

Awesome sleuthing and follow-ups!

[Tom]

Sounds like great progress. Mounting the alarm box to the hvac duct with screws sounds about right for alarms of that era -- mostly installed by stereo shops and/or places like circuit city back in the day. I'd yank it out. They account for 29.64% of all 944 no-start problems, and haven't prevented a car theft since 8-track tapes were popular.

Believe it or not, that wooden floor board is stock, or a close replica...

Without the O2 sensor, your idle maps might be a bit lean, especially if there are even tiny vacuum leaks anywhere (including throttle body seals). I'd fix the O2 sensor and then see where you are...

[PSU_Crash]

Sounds like great progress. Mounting the alarm box to the hvac duct with screws sounds about right for alarms of that era -- mostly installed by stereo shops and/or places like circuit city back in the day. I'd yank it out. They account for 29.64% of all 944 no-start problems, and haven't prevented a car theft since 8-track tapes were popular.

Believe it or not, that wooden floor board is stock, or a close replica...

Without the O2 sensor, your idle maps might be a bit lean, especially if there are even tiny vacuum leaks anywhere (including throttle body seals). I'd fix the O2 sensor and then see where you are...

O yeah. The security brain has been removed and a few relays also put back to factory. As I go through things I'll pull all the wiring and sensors. No more driving it and having the 4 ways randomly come on, or having a guy at work say did you leave your blinker on in the parking lot? I also agree with them being useless.

So that board is stock!? Huh, never would have guessed.

I have the new Bosche O2 and I intend on using it. Trying not to drop the exhaust to really get at it.

Speaking of vacuum leaks. It sounds like a leak under the intake at idle. Any movement off the TPS closed switch and the sound goes away. Maybe I'm just hearing flow through the ISV? Maybe I didn't tighten the hose under the manifold ... I will be looking.

[PSU_Crash]

Update time.
The O2 was a serious PITA to get out! 3 days of PB, heat and beat until it finally broke free. In the mean time I also turned the throttle stop in half a turn and reset the TPS. Cold start is rough for a few seconds and then evens out around 1k RPM. Seems to be somewhat better, but it might just be in my head.
Cold start


While hunting wires for the security system I had the console apart so it was time to figure out why the radio didn't turn on. It had power, but nothing. So I bought a cheap android auto head unit from wal-mart to get me going. Powered up and still no sound. Meter time. All speakers measured just over 4 ohms, so we should be good, right? Nope. Rear passenger wires also measured a dead short to ground. Disconnected that speaker wire and violla! It works! Down a speaker for now. That's a later problem.
FYI if you wire in a stereo like this, you are the problem!


So after that it was time to install the shifter, short shift and linkage from only944. I underestimated how difficult it would be to get to everything. I got it after a few hours and I can't believe how tight the shifting is now!!! I used to be able to put in in 1st and easily move the shifter to where 5th should be, or more. Now, it's so much better than I had hoped for. Kyle, you ROCK!!!
Tell me safety wire on the set bolt that holds linkage to the shift rod is not factory. Getting that wire off was almost the most difficult part of the job. I bled and cursed, a lot.


This was the main issue, although every moving point on the shifter/linkage had slop.


Tracked down the no wipers issue. After checking through the system and finding power all the way to the wiper motor, I smacked the motor with a wrench and it started working! ... while making terrible noises. I will be attempting to pull that apart and clean it up soon.

Next we are on to the odometer. Seems like it's just a gear. That should be easy. Well, when I got it apart I found this.




Ahh gears that are now dust. My favorite. Now I'm not real sure how to figure out what gear needs to be there. Trying to count teeth on the mating gear is going to be difficult without further disassembly I fear. Any suggestions?

On a high note, I have put about 200 miles on the car now and decided it was time to test it. There is still a little something from 3.5 to 4k RPM. After that it pulls clean to redline and feels great! Driving this car is truly a joy

[Tom]

Great progress!!

That start up video sounds pretty good to me! Just FYI, YouTube links embed automatically without the URL tags (and don't embed with the URL tags) so I took them out. The shifter video reminds me I still have those replacement parts I need to put in mine.

I think in the 80's and 90's, everyone was a self-proclaimed stereo and alarm installer expert, no matter how little they actually knew about it. It seems like most 944's look like that behind the stereo, at least until someone comes along and fixes it.

Assuming your car is a US model, there is a 99.63785% chance you need the 21-tooth gear. I still have a bunch of them I printed in fancy ceramic-like resin and would be happy to send one your way. It should last longer than the car...

[O875]

Tell me safety wire on the set bolt that holds linkage to the shift rod is not factory.

You're doing excellent work here.
However, I have some bad news...

Screenshot 2025-05-16 at 17.41.18.png (595.96 KiB) Viewed 595 times

The lock wire is indeed factory.

[PSU_Crash]

Tell me safety wire on the set bolt that holds linkage to the shift rod is not factory.

You're doing excellent work here.
However, I have some bad news...
The lock wire is indeed factory.

Thanks! It has been a lot of work and I'm not done yet.
Never would have guessed that wire was stock! It did not get one back on it. Just locktite.

[PSU_Crash]

Great progress!!

That start up video sounds pretty good to me! Just FYI, YouTube links embed automatically without the URL tags (and don't embed with the URL tags) so I took them out. The shifter video reminds me I still have those replacement parts I need to put in mine.

I think in the 80's and 90's, everyone was a self-proclaimed stereo and alarm installer expert, no matter how little they actually knew about it. It seems like most 944's look like that behind the stereo, at least until someone comes along and fixes it.

Assuming your car is a US model, there is a 99.63785% chance you need the 21-tooth gear. I still have a bunch of them I printed in fancy ceramic-like resin and would be happy to send one your way. It should last longer than the car...

Thanks Tom! It has some whine to it, so when I go back to check timing tension I will have to re-adjust the balance belt anyways. I didn't think it was too tight, but it is a little loud I think.

Appreciate the youtube link and gear info, I'll shoot you a message about it.

[PSU_Crash]

While tidying things up for a cruise in tomorrow I changed the oil and filter. Then decided I need a base line compression reading. It hasn't run in several hours. Still warm to the touch.
#1: 155
#2: 157
#3: 157
#4: 154

Seems a little low, but it's even enough so I'm not concerned. I may test again with the engine at temp