[Charles Geer]

Here are pics of my newly modified oil pickup tube. I will be performing this modification for a small fee.



Notice the crack at the base of the old oil pick up tube. This is a common problem in 968 race cars that are being run at 9/10 ths and 10/10 ths RPM range.



The damaging resonance in the 968 3 liter motor comes from its lack of the 944 S2 harmonic balancer ($450 from Porsche)



Replace your harmonic balancer with the 944 S2 unit (PART # 944 603 194 .1R) which weighs 5.5 lbs. Your motor will spool a little slower (and you may loose 1 hp) but you will be able to beat the crap out of your engine during the race.



Retension your balance belt before every race.



Replace your old oil pick up tube with the new modified unit.

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[Charles Geer]

Sorry Pics did not come out...new camera. Will try later

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[Anchorman]

This is timely, Charles, as I'm expecting to be dropping my oil pan next week. Can you deliver that quickly? (Just kidding - sort of.)

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[Charles Geer]

[quote name='Anchorman' date='Apr 11 2006, 03:13 PM']This is timely, Charles, as I'm expecting to be dropping my oil pan next week.  Can you deliver that quickly?  (Just kidding - sort of.)

[right][post="18955"]<{POST_SNAPBACK}>[/post][/right][/quote]



Give two to four weeks after I receive your new oil pick up tube. The price for me to do it is $425.oo. If you attempt this yourself be sure not to put too much heat in the weld or the thin metal will be perferated.



E mail me direct or call me if you want to have this surgery done.



678-462-1177

cgeer7@aol.com



Pics are on the way...I think I have to shrink em.



Charles Geer

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[Anchorman]

Charles, I've sent you an email. Thanks, Jim

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[Anchorman]

Here are photos of Charles's modified oil pickup. Nice work.        

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[flash]

i am wondering if the reason they crack is that the bolt at the lower end by the screen is not attached to the block

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[Anchorman]

What is the bolt and strap at the pickup end there for? Is it a clamp mechanism holding two pieces of the pickup together? If so, it would seem to give a bit of a pendulum effect that's probably not helpful. Can that bolt be used as the connection point for a strap to someplace in the pan? Just thinking without ever having seen the actual parts.

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[Charles Geer]

That bolt attaches to your oil level senser...It's useless, and could be used as additional bracing. The oil pickup tube will snap at the base (see photo), mainly because the heavy end sticks out at a 45 degree angle to the light end.



This is the same oil pick up tube in all 944's. Again the resonance shakes the heavy end until the base fatigues..eventually braking in half.



Be sure to get the 944 S2 harmonic balancer.



But don't ask your dealer for a "harmonic balancer" for they won't know what you're taliking about. Ask for it by the part # (shown in previous paragraph).



This 5.5 lb piece reduces sound and vibration frequency enabling the 968 engine to reach it's full potential.



Porsche thought that they could remove it since they lightened the inner parts of the 968 engine for better balance and performance...THEY WERE WRONG.





As long as you don't keep your stock motor above the 90 % RPM range you will not need this modification.



If you keep your revs at the maximum, especially during downshifts...you will need this modification.

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[flash]

and that is why i am VERY interested in such a mod - i looked at this from a different pic, and thought a bracket or triangulating piece connected to the lower tab was a no brainer solution - any reason you didn't take that approach?

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[mitch968]

Charles, is that the correct part number for the harmonic balancer? Can't seem to find it at pelicanparts, which usually has most parts listed.

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[Eric_K]

What is the bolt and strap at the pickup end there for?

It attaches to a tab on the oil return tube. The two tubes together form what looks kinda like the letter A. I would have thought the bracing from the oil return tube would be enough to keep the pickup tube from flexing in the direction of that crack. Guess not.



Charles, you make it sound like the sky is falling. <img src="/forum/images/smilies/968/tongue.gif" class="smilie" alt="" /> I know from personal experience, the 968 can be raced for a long time at high rpm without this happening. That's not to say it won't happen, however. It looks like a good mod to do.



$425 for welding a tab on? I must be missing something.



Eric

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[orphanowner]

[quote name='Eric_K' date='Apr 12 2006, 09:31 AM']It attaches to a tab on the oil return tube. The two tubes together form what looks kinda like the letter A. I would have thought the bracing from the oil return tube would be enough to keep the pickup tube from flexing in the direction of that crack. Guess not.



Charles, you make it sound like the sky is falling.  <img src="/forum/images/smilies/968/tongue.gif" class="smilie" alt="" />  I know from personal experience, the 968 can be raced for a long time at high rpm without this happening. That's not to say it won't happen, however. It looks like a good mod to do.



$425 for welding a tab on? I must be missing something.



Eric

[right][post="19017"]<{POST_SNAPBACK}>[/post][/right][/quote]



Eric is 100% correct here. The oil drain back tube triangulates the oil pickup tube. The curious tab that someone said is for the oil level sensor is in fact positioned solely to bolt the screen end of the pickup tube to a corresponding tab on the drain back tube which ties them together with a 5 mm bolt. FYI, the pickup tube bolts to the block cradle with two bolts and the drain back tube bolts to the opposite side with a single bolt, triangulating the structure.



I would argue that the stock setup is nearly bulletproof. The only time I've seen pickup tube failures is on racing engines not running balance shafts and even in those situations solid motor mounts and the old style (not reinforced pre-87) pickup tube were contributing factors. I have first hand experience with a 968 engine 944 racecar that was the "severe duty" poster child for the 968 engine. No balance shafts, special cams, higher compression, solid motor mounts and a stock unmodified oil pickup tube.



Personally, I'd be very hesitant to replace a proven factory part with someone's idea of an “improvement” unless there is significant evidence that the improved part reduced the incidence of failure. I'd also opine that $425 sounds like a lot of money to weld a gusset.

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[Charles Geer]

My apologies for stating that the bolt attaches to the oil sensor. I watched my mechanic attempt to remove the Oil Pan to get to the bottom end of the engine and he mentioned that the sensor had to be removed or the pan would not drop. I thought that was what that bolt was for.



I don't recommend this mod for everyone.



95% of the 968 racers in PCA don't brake this part.



These are the individuals I know that have.



Donna Amico: F Stock racer (works for PCA national) snapped oil pickup tube while

GT3 driver Gary Church was driving car at PCA Club race Carolina Motorsports

Park in Fall 2004. Suffered terminal engine failure. Rebuilt engine with new

S2 balancer and newly braced pickup tube. Sold car for 964 racer.



Gary Grigsby: F Stock Racer (Highly developed 968 and credited for coming up

with the idea to brace the oil pickup tube). snapped oil pickup tube during

race. Noticed his variocam sounded a little suspicious at idol and shut the

engine off before engine could damage itself.



Charles Geer: Snapped oil pickup tube during Sebring Club race. Did'nt know it

because car ran strong. Asked this Forum why variocam was noisy at idle

and FLASH mentioned that it could be the oil pickup tube. Ran race at

Road Atlanta upon which idol variocam noises got worse. Dropped the

Oil Pan after race...Oil Pickup tube dangling as shown in pictures...

Bearings fried...suprised the engine could run on oil bubbles.



I posted the pictures to show what could potentially happen. Eric...you've got the most reliable 968 I know of...send me your luck.



Any good weld shop can do it. But if they don't want to try it send it to me...be glad to help. <img src="/forum/images/smilies/968/blink.gif" class="smilie" alt="" />

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[Charles Geer]

[quote name='mitch968' date='Apr 12 2006, 08:23 AM']Charles, is that the correct part number for the harmonic balancer?  Can't seem to find it at pelicanparts, which usually has most parts listed.

[right][post="19009"]<{POST_SNAPBACK}>[/post][/right][/quote]



We got this number from diagrams on the PET (Porsche OEM Parts) workshop manuals.



Try calling your Porsche dealer. We go quoted $450 for the S2 Harmonic Balancer.

Using that part number.



It is the pulley attached to the crankshaft that pulls the "large" serpentine belt.

It look just like the 968 but it is a different part number as well as a different price.



You can get it from a junk yard but I don't want to take any chances so I'm going new.



Part will come from Germany since it not highly requested so give it a few days.

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[Charles Geer]

[quote name='mitch968' date='Apr 12 2006, 08:23 AM']Charles, is that the correct part number for the harmonic balancer?  Can't seem to find it at pelicanparts, which usually has most parts listed.

[right][post="19009"]<{POST_SNAPBACK}>[/post][/right][/quote]





AFTER FURTHER REVIEW.



Mitch you're right...I was reading from the wrong notes...





THE CORRECT PORSCHE 944 S2 HARMONIC BALANCER PART # IS



(drum role <img src="/forum/images/smilies/968/biggrin.gif" class="smilie" alt="" /> )



944 102 123 06



You still may have to call Porsche

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[mitch968]

Wow, that's one pricey pulley. Is it just like the original pulley, except heavier?

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[Charles Geer]

[quote name='mitch968' date='Apr 12 2006, 12:42 PM']Wow, that's one pricey pulley.  Is it just like the original pulley, except heavier?

[right][post="19046"]<{POST_SNAPBACK}>[/post][/right][/quote]



I have'nt compared the two in person yet but I have had the part explained to me.

Here is my interpretation:



Most harmonic balancers are made of part rubber / part metal. it is designed to absorb negative harmonics like a sponge.



BMW M3's use a similar device, a metal pulley loaded with rubber inside.

Although it doesn't get rid of all vibration it simply reduces it to a usable level.



Bad Harmonics in the 968 can cause the following problems.

1) Fracture Mufflers and Exhaust.

2) Crack Flywheel bell housing

3) Snap power steering tensioner (located close to lower balance shaft)

4) Brake Alternator mount from engine (located close to upper balace shaft)

5) Fracture oil pickup tube.



(If you don't have any of the symptoms you probly don't need the S2 Harmonic Balancer)



ALL SIX happened to me over a six month period.

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[Lemming]

[quote name='Charles Geer' date='Apr 12 2006, 11:08 PM']ALL SIX happened to me over a six month period.

[right][post="19082"]<{POST_SNAPBACK}>[/post][/right][/quote]



Are you sure that's not from jumping curbs <img src="/forum/images/smilies/968/ohmy.gif" class="smilie" alt="" /> Sometimes I think you would rather be rallying <img src="/forum/images/smilies/968/huh.gif" class="smilie" alt="" />

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[Brett968]

It seems that cracking oil pickup tubes are in fact a real problem. How do I know? Well, this happened to me. After chasing an incessant variocam noise (only happened at idle and not all the time) and after replacing the Variocam assembly (previous owner), and timing chain (me), I finally found the culprit while doing the oil pan gasket. The pickup tube had a crack in it in exactly the spot described. The engine always had good oil pressure but obviously the oil was getting aerated and small bubbles of air were getting into the variocam assembly. Since air is, of course, very compressable this was causing the light occasional tapping at idle. After swapping the oil pickup tube for a good unit I have never heard a single noise out of the variocam.



Brett

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