REBUILDING MY CHEAP WRECKED PORSCHE GT4 PT2

YFOOD LINK: bit.ly/SavingS...
DISCOUNT CODE: SALVAGE-KZbin
In today's video we start tackling the suspension and brakes to get the car able to roll, we also start stripping to assess the damage.
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[@projecteuroau]

About the shaft. I’d probably do the following 1. Remove the opposite side and measure that one and inspect. 2. Check the part number of the replacement is correct. 3. Scope it with a camera and see if you can see any of the old shaft inside 4. Chat to Porsche and see if there is a trick to installing Best of luck mate 😊

[@jonviol]

The rear shaft can normally just push/click push into place -like any other. The thing sounds as though it' hitting metal. Use a vernier caliper and do a depth measure to prove space exists. Is a chunk of the old shaft still in there?

[@Sanz_1009]

"Stress fractures" 😂 Thanks for making my night

[@squeakers27]

Gearbox flange is a very tight fit, would recommend putting in the freezer to shrink it slightly and hope it works.

[@Luke_lw]

There’s a John deer mechanic called zk master tech when they fit shafts they freeze them and then head up the inner part with a torch or special heater to expand it

[@lentner3]

Make sure there isn’t any obstruction first

[@sparkplug964]

I would try and get some dry ice and then give it another go.

[@Original_Nuttah]

Have you got a bore scope? Might be worth checking inside the gearbox, as previous people have mentioned you might need to remove other shaft to fit but doubt that as the it doesnt go in enough to recieve circlip. The fact the whole wheel and hub was ripped off the car could have damaged the box/diff

[@wcads623]

You need to check if there is broken piece of spline from the original hub still in there. If you take the opposing hub/driveshaft out you may be able to knock the opposing broken spline out - or not. Otherwise it may be gearbox/diff strip down!!

[@PedroMcMahon]

Stick the flange in the freazer for a day or two then try it. Have you put your mini camera in to see if it has a old bit of metal still in the drive shaft

[@EatSleepShift]

With the shaft, if nothing else works maybe try putting it in dry ice, and putting it in like that without much force

[@conorturton]

Get a screwdriver, stick it in the hole in the gearbox, measure how far it goes in then compare to the flange. Might be some of the old flange shaft that's snapped off. Could be simply a case of drilling a hole in the snapped off bit left stuck in the gearbox, tapping it, chucking a bolt in and pulling it out.

[@izalman]

Don’t hammer the end of a threaded shaft without the nut being fitted. You may mushroom the end slightly and not get the nut on afterwards and it’ll give a false torque indication when tightened.

[@davidg2073]

Dean loving the rebuild of the GT4. As for your drive shaft problem I would suggest you use your boroscope to determine if either the original circlip or a piece of the original shaft is still in place. It should be possible to extract either without the assistance of a gynaecologist by removing the opposing item and knocking through. On a word of caution please check for seal damage and definitely ease up on the hammering unless you have very deep pockets. On the brake conversion you will have to do some recalibration to accommodate your change from ceramic to steel. Finally just to highlight the obvious plus side, you will know the sale of the surviving discs should more than cover the cost of the conversion.

[@andreispt96]

maybe you have a leftover piece from old flange on inside the gearbox and that is the reason why it don't fit

[@ianp369]

Big project, glad you show the issues and proving everything is not a simple bolt on job. I think you are at £36,723 total spent so far.

[@NWSTRX850]

Some days it’s just better to walk away and have a beer!

[@davidmorgan8171]

Hi Dean, try taking the spring clip off he flange and try to see if it will go all the way in. If it fits then your problem is with the circlip which you could try squeezing up in the vise. if not you will have to look deeper into the gearbox. Best of luck.

[@xxsekoxx]

There was a transmission recall on some of these. Make sure this one has the replacement one in.

[@cp4512]

You’re doing great. I’m really enjoying watching.

[@ep91monster]

Probably some of the old spline stuck in there, drift it out from the opposite side if you can. Could drill, tap and stick a bolt in and slide hammer it out but you'll need to clean the swarf out some how

[@veelside200sx]

Make sure you don't push it in and out the workshop without the end of the drive shaft bolted in the hub to hold the wheel bearing together, otherwise the wheel bearing will collapse as its the drive shaft end, (the bolted cv joint) that holds it all together. Love the channel, Steve@Drive Autoworks Poole.

[@blitzsah]

Loving the content, only discovered the channel a couple of weeks ago, just wondered where you learnt about cars. You seem very knowledgeable, especially compared to some other KZbinrs.

[@SavingSalvage]

I started off as an apprentice HGV tech 15 years ago and went from there bud 👍🏽

[@Markymarkvinylnut]

Brilliant video..looking forward to the next one

[@auwz66]

Pretty sure to get that flange on you will need to pull the main shaft which is on the drivers side first. Then put the flange in the near side (minding the seals which are probably now toast...) and then slide the main shaft in from the drivers side. Before you do anything you need to closely inspect the seals to ensure you have not damaged them. HTH.

[@SavingSalvage]

Yeah I’ll try and remove the otherside and have a look

[@rob612]

@@SavingSalvage To be honest i was about to say the Same thing myself as auwz66 did, Dean the seal would be 100% toast at least you can bond the body work yourself Mat Armstrong did slightly the same repair on the same side as well

[@fluffstar_]

@Saving Salvage I’d clean the both m and f side of driveshaft and clean and re grease the o-ring with plenty of grease so that it stays aligned correctly when you’re putting it in. The video shows it rebounding when you’re whacking the old driveshaft. Hope that helps. Good luck 🤞

[@timnewman7657]

Check if nothing remains from old flange in the gearbox

[@davidcollins9350]

Your honesty is brutal but brilliant

[@abdulvalimahomed5496]

Hi Mate, I think May Armstrong is looking for Ceramic Disc for his Porsche build as one of his brake discs is damaged. Might be great idea 💡

[@SavingSalvage]

Thanks bud! Already asked him. He’s bought one already

[@Dalbayob69]

Put the flange in freezer overnight and use heatgun to warm up receiving end on gearbox. Hope that works👍

[@cccpkingu]

That is also not coming off easily.

[@Dalbayob69]

@@cccpkingu that’s why it’s called press fit.

[@QPRRhino]

Check for remains of the old flange, may have snapped. Probably not but worth checking.

[@seanb9814]

I do empathise Dean, I've had plenty of 'those days'. Your persistence will win out though! Another good video.

[@richhelm21]

If the d/shaft flange is coming hard up against a stop, as others have suggested, it is likely the old stub snapped. Use a bore scope to look inside the box & confirm. If it has it will be tight, being as it will likely be deformed or twisted when it snapped. You will need to drill is (tungsten carbide bit) tap it and use a threaded attachment on a small slide hammer to extract the broken part. Hope you get it out Dean. loving the build so far 👍

[@michaelcook1923]

Dean you need some Guniwheels these help you move car's about when you have no wheels for the car. Keep going starting to look good.👍👍👍👍👍

[@dmarriott9701]

We all have had those days Dean, part of life so I’m told. Looks like the workshop floor hasn’t tidied itself lately

[@leighpowell2426]

We all have those days bud! The fun of Copart cars. Keep the faith 👍🏻

[@LAIRDY67]

Feel your pain top man for letting us see the bad day good luck going going forward mate

[@omar90444]

Keep up the good work. The videos are getting better and better. Changes like the additional commentary and tougher projects you’re working on are great.

[@scatmanjohn895]

It’s just a guess mate, but I think the spline has snapped off inside the socket from the old driveshaft which is going to be a nightmare if I am right, I hope I am wrong. Good luck my friend

[@kieraz10]

I was about to suggest the same thing.

[@baggedr32mk5]

Decca heggie does cars now 🤣

[@shauneco]

Bingo

[@davog1946]

Sounds plausible for sure. Strong magnet might do depending if the circlip is in there or not.

[@mktrollop1093]

​@@davog1946 magnet definitely won't do it, maybe he could Drill and tap it or something

[@johnwren5516]

Dean we’ve all had one of those days , but you plugged away the next day and made good (but expensive) progress . I’m a plus one for a piece of the old shaft being snapped off and stopping the flange going in . If you haven’t got a bore scope you might even be able to get your phone to take a picture to see if there’s anything in there , I hope not

[@jeffshaw4553]

What a nitemare you had but it’s gonna look amazing when it’s finished if it’s any where near as good as your mrs vw you done your brave taking on this salvage your a very brave man but good luck to you 👍🏽👍🏽

[@garysimpson8860]

Rebuild the drive shaft , I broke my cv joint on my track car and it was 1200 quid for a new one but sent it to a company who rebuilt it with new bearing etc for 200 quid 👍

[@phil7301]

I'm a really experienced mechanic,, I changed my wiper blades last week !! I will tell you what you should do 🙄🤔, keep up the good work 🏴󠁧󠁢󠁥󠁮󠁧󠁿🏴󠁧󠁢󠁥󠁮󠁧󠁿👍😁

[@PompeyMatt17]

I'm hugely impressed you said "rent-a-rim" in one take...😄😄😄

[@sebastian993]

hate days like that. sadly every day of my life is like that

[@gjek6355]

Possibly try taking other side driveshaft out of diff and try looking through, some diffs are open allowing sometimes access to possibly knock a snapped driveshaft end out , would not know if Porsche set up allows this, I had similar issue with a bmw 6 series many years ago , from that I was able to see a misalignment issue , thus helping me make a replacement diff or repair decision, good luck

[@bealzibub4002]

Could the end of the old flange still be in there?

[@andygray563]

Insert something into the gearbox and measure the depth to check that it can take the drive shaft freely. Or else insert a prove camera in and inspect inside. As others have suggested, possibly something us snapped off inside. So before forcing more investigate if clear to accept that shaft depth freely.

[@ElliottBrooks]

Enjoying the new style of content you're going with - Looking forward to this project + hope to see more of the M2

[@paulthompson5416]

🤔Stress what Dean 🤷🏼‍♂️ 😂😂😂 that was just one of those moments 😂😂😂 Good luck bud 👍🏼

[@marklloyd1737]

Oh and keep up the great content, you're juggling so much I don't know how you sleep at night!

[@Lemma01]

Loving the details on this build. Will be worth it - the only question is how much value will be left in the car when you've finished. I suspect five figures, so keep smiling!

[@recs5351]

Check the splines inside the gearbox (spline depth) it sounded like you were hitting against steel, is it possible the original one snapped from the impact?

[@TheOriginalDaveJ]

I heard that, last couple of hits 'ting ting'

[@edwowen]

You have more patience than me! Good luck, I'm sure someone will know how to get that in without a hammer!

[@charliedanvers123]

I agree with some of the other comments, something is definitely restricting the flange from going in. I think the next step would be to have a visual inspection with a torch in the gearbox for anything which could restrict the flange from going in. Also, do you have the old flange to inspect to check the condition? If the old flange is ok you know none of it has fractured.

[@seanfarrell6009]

Nice update sorry to see you having "one of those days" but made great viewing, I'm unable to offer any advice on the issues you are having but look forward to seeing you resolve them

[@jonnyduncan7056]

Top work.. Your attention to detail and knowledge is amazing..

[@billionone4100]

Get the new shaft you bought for £85 reconned from a driveshaft place they will be able to put in new bearing etc so it is useable

[@perfektrepairs7934]

I bought a Mk5 GTi golf from copart had same issue couldn't fit new drive shaft got quarter way in and stopped, turns out the splines had broke in the crash it had and snapped a small section inside gearbox I drilled into the centre of it then used a opposite thread drill bit that allowed me to pull it out

[@jamest5149]

Can you see if there’s anything left in the splines from the old drive shaft when it broke… try measuring the the distance the flange has to go in then measure the available depth in the gear box, there could be a piece of the old drive shaft in there. Also another thought…, and more likely…. the the flange splines hold the diff gears in place, they could have moved out place when the car has been moved around after the drive shaft was pulled out in the accident…. Measuring the available depth with calipers or even just a extension bar or something that will fit in should show you where to start 👍

[@colinhebden]

Re rear hub not going in. Measure and check length and compare to hub. If tòo little depth use your boeoscope to see why. On cars when a drive shift broke, you often had to remove the other shift and pass around through the diff to knock out the broken piece. This may work in your case. Also by removing the good side you can see how it's meant to fit. Good luck

[@leonardgoldberg2879]

After hearing the prices of two brake discs , it makes me glad that i own a 21 year old Astra G.

[@nigelw598]

Gday Dean, We’ve all had those days in the garage. Best to head home and clear the head as you did. Have you got a slide vernier that you can check the depth of the rear drive shaft slot into the trans? Make sure not binding on something as it was obviously trauma-ed out. Possibly the old shaft has sheared the end off? Borescope camera too perhaps to check if you can see a sheared surface in there? All the best, Cheers 🍻

[@GRfourfun]

Fair play to you Dean, this is one hell of a project. I’m a bit miffed that the discs for the front are £100 cheaper than my GR Yaris!

[@mathewrobinson2741]

If the out put flange shaft isn't going in you need to check your circlip on the flange is in good serviceable condition and check the receiving end inside the gearbox, these things should engage up and you'll feel it collect the circlip and then it should pop in, I wouldn't bash it incase you damage the splines inside the box

[@davidevans-gy5rt]

Always turn the drive shaft when hitting home also try it with out the clip on first

[@broken12367]

On the plus side you can sell the ceramic disc and callipers. We’ve all had those days Dean.

[@MrHuismeester]

Oef....a typical Monday where everything is going wrong, and the day ends you find out you did nothing.....luckily there are more days in a week and the next day you did some fine repair . And yes.....expensive , those super cars are not only a big price in the Showroom but also in parts.Still you being optimistic and that is the only cure on a bad day !! Fingers cross no more body ,s out off the closet ! See you next time !

[@GoWstingray]

Daft question, but if your new after market discs are for the GT4 that had carmics as well would the existing yellow calipers be the ones you need to use or have you tried both?

[@keithbrookes3229]

Try dry ice on drive shaft heat gear box with heat gun looks like it could be interference fit on bearings

[@jay73jb]

Aww mate I feel for ya.its gutting when you have days like that.

[@GlennBerry]

You can always flog the good pccb disks to recoup some money. 🙂

[@rafn]

Dean maybe old flange sheard and you still have a small piece of it on the gearbox?

[@natesimmons8241]

I'm no expert... But question - do most body repair shops before cutting away metal pull out the damaged material first with a hydraulic ram or frame machine. I think it helps releive stress across the entire car and helps to get the chassis as whole closer to square before cutting and welding anything new back in. Just 2 cents from a backyard hobby mechanic!

[@civicvtec92]

36,723 running total in case anyone wondering 😂 Awesome video buddy, looking forward to seeing this complete 😎

[@johnelbro127]

Another great informative video. Look forward to next one. 👍👍👍👍

[@bigbhp6808]

Check cars in neutral before inserting flange may be worth trying that

[@70scoff]

Regarding the drive shaft, I would take out the other side and compare them, I know some drive shafts have smaller stubs on one side as the gears are offset.

[@stumps8672]

I take it the ceramic discs that come off the car can be sold on.

[@tlabort]

what about taking the drive shaft from the other side and seeing if they fit visa versa and matching them up

[@thomastime9446]

As you do it it just looks like I could do it. The word being looks. Nice work and nice to watch

[@walbrzych9975]

You will have to take the drive flange out from the other side, compare them side by side, then you can have a look through the diff to see if there is an obstruction and if there is try and tap it out with something.

[@electromecapassion]

You need to put the flange into deep freezer and eventualy heat a little bit the gearbox side that should do it

[@dubiousricardo]

Not a bad price from Porsche for ceramic discs! I've seen them advertised at an indi for £18,000 a set, although CFRC! Great work.

[@matsleight]

You can go surface transforms instead of ceramics for the disks

[@KozyOnCars]

Going to agree with a few others, think the reason its missing is that it snapped off inside the flange when the accident happened. So its impacting the other half that is left in the gearbox. Would be the only explanation. Hope that isn't the case.

[@Jasonj___8]

Yes Deano!!! I’d watch these clips if they were 90 mins long keep them coming!!🚒👍

[@dwrowley]

Great video, looking forward to seeing more videos

[@conorturton]

Thank god you're going to steel discs....just madness for ceramics you'll get no benefit from if you're not doing track days. Good news is that one single unharmed ceramic left on the O/S/F should fetch a good few bob on Ebay and pay for a chunk of parts.

[@eamonkelly2792]

When you were having the bad day, I thought you were going to hit your hand with the hammer, you are making great progress, 👍👍

[@SavingSalvage]

I did 😂

[@eamonkelly2792]

@@SavingSalvage 🤣🤣🤣

[@lukeframpton3671]

You need to unbolt the shaft from the flange put the flange in by hand you will feel it line up then give it a good crack with a copper hammer just look inside first to make sure the gear's haven't dropped take the weight off the other shaft I have a 911 and I had to pull the box to do the uprated imput shaft bearing

[@carbide1]

Warning, do not hit the drive shaft which is threaded on the end with a hammer you could damage the end of the thread. Put a nut on the end of the threaded shaft so it protrudes out past the shaft it protected the thread.

[@stephendavies7805]

Fair play mate your keeping your cool,,,, Christmas lights r enough for me to throw a major wobble 🏴󠁧󠁢󠁷󠁬󠁳󠁿👍

[@richardtaylor2449]

I am hoping Dean you've had a quick look under the bonnet at those strutt towers... thanks for the vid' and the Cerbera too

[@Jason-zh7wo]

Good luck with the gearbox 🙏🙏

[@PGriff]

Don’t try and push the car without a driveshaft in to hold the wheel bearing together mate - you’ll knacker the wheel bearing. Also, have you tried rotating the gearbox a little? You might find with a bit of ‘jiggling’ the splines will line up and you’ll be able to tap the output flange in with the hammer. Good luck 👍

[@philipdavison3862]

you should be able to sell the good ceramic discs to someone needing odd ones.

[@Carlos.G]

Try your old callipers from the ceramic disks with the floating disks 👍

[@SavingSalvage]

2 yellow and 2 red calipers! Would looks funny 😂

[@trickyrat483]

@@SavingSalvage But respraying two calipers is a lot cheaper than changing the disks. :)

[@SavingSalvage]

@@trickyrat483 it’s done now, can’t send them back. Lesson learnt! At least the brakes a full factory set up though.

[@valleystaff7031]

Strick your borescope in the driveshaft hole and have a look whats going on..May be some debris in there.

[@gsmdo8836]

Great episode. When you are having one of those days, the ONLY thing to do is walk away - well done. You should be able to flog your surviving ceramic discs and calipers to defray some of your costs?

[@andrewkidger7048]

Bit of Stressh!! there Dean, there must be something still stuck in the gearbox stopping the flange from going in, cars coming on ok though, hopefully the chassis leg can be pulled ok, looking forward to the next dose !!, Well done Dean.

[@stevo4649]

thankyou Dean this project is fantastic content for us,,but what a drama for you,,👌 also some very helpful comments ,,,,👍👍

[@adrian.adrianl6401]

Design911 are the best for all the Porsche spares .

[@tristanpage6805]

Great content. Look forward to the progress

[@HuntsChris]

It sounds like that one ceramic disc and calliper could pay for the switch to steel, assuming you can find a buyer. Can you run the endoscope in the gearbox to see what’s stopping the drive shaft seating properly?