AOS Frustration - 986 Forum - The Community for Porsche Boxster & Cayman Owners

neumaiek · 04-15-2019, 06:49 AM

Good morning!

2002 Boxter S with 90k miles has a really bad AOS that I am in the process of replacing. Big problem for me is releasing the clamp on the outside of the AOS. Yes, it is in a really bad place to get to but it seems as thought that "squeeze" clamp is just not willing to release. I am very very careful not to do anything that could break that fragile clamp. I am not even concerned at thi point about the clamp at the bottom of the bellows until this issue is solved.

I do understand that this repair is a huge pain but are there any really good approaches to it? I have spent a lot of time on YouTube and any internet resources figuring it out but yes, it is all the same. No one talks about the clamp issue.

Thank you for any time and attention to my challenge here.

Kurt

husker boxster · 04-15-2019, 06:59 AM

That squeeze clamp is a huge PITA. Once I got mine released and the AOS out, I removed that clamp and threw it as far as I could and replaced it with the screw type clamp. Makes future replacements tremendously easier.

Good luck with getting it released. Not much that can be relayed for help other than stick to it until you get it.

tonythetiger · 04-15-2019, 07:03 AM

Do you have good hose clamp pliers?
I think it is impossible without the cable-type Hose clamp for reaching up there. Best 15 bucks you'll spend

Starter986 · 04-15-2019, 09:21 AM

This isn't rocket science, I believe. I'm not understanding why anyone wouldn't just cut the bellows and pull it out. Then, get your hand in there and remove the clamp. Voila! Magic. An illusion?

I mean, a new one is going back in and with that handy blue-pull-clamp... done.

Might save some serious time. I know it did for me.

Black Knight · 04-15-2019, 09:32 AM

Quote:

Originally Posted by Starter986

This isn't rocket science, I believe. I'm not understanding why anyone wouldn't just cut the bellows and pull it out. Then, get your hand in there and remove the clamp. Voila! Magic. An illusion?

I mean, a new one is going back in and with that handy blue-pull-clamp... done.

Might save some serious time. I know it did for me.

that is what I ended up doing

neumaiek · 04-15-2019, 01:13 PM

Quote:

Originally Posted by Black Knight

that is what I ended up doing

I haven't arrived at the bottom of the AOS and the bellows clamp. I am severely stuck on the crankcase vent hose "squeeze" clamp on the outside of the housing. It seems like after al the miles that it isn't compressing properly. I can't imagine the work required if that clamp breaks and it all needs replacing.

Yep, I am saving the bellows part for last after the bolts are out to just yank it. I have the new clam provided with an attached clamp as part of the whole package from Pelican! The upper hose to throttle body was messed up too.

Thanks!

Jager · 04-15-2019, 07:01 PM

Quote:

Originally Posted by neumaiek

I haven't arrived at the bottom of the AOS and the bellows clamp. I am severely stuck on the crankcase vent hose "squeeze" clamp on the outside of the housing. It seems like after al the miles that it isn't compressing properly. I can't imagine the work required if that clamp breaks and it all needs replacing.

Yep, I am saving the bellows part for last after the bolts are out to just yank it. I have the new clam provided with an attached clamp as part of the whole package from Pelican! The upper hose to throttle body was messed up too.

Thanks!

This makes the spring clamp removal/installation much easier:
https://www.walmart.com/ip/2-Flexible-Wire-Fuel-Oil-Water-Hose-Clamp-Plier-Tool-with-Long-Reach/560657210?wmlspartner=wlpa&selectedSellerId=529&adid=22222222227110113236&wl0=&wl1=g&wl2=c&wl3=233467549918&wl4=pla-385747018796&wl5=1014254&wl6=&wl7=&wl8=&wl9=pla&wl10=112354406&wl11=online&wl12=560657210&wl13=&veh=sem&gclid=Cj0KCQjw19DlBRCSARIsAOnfRei97w7OFi45ECUNIL_R 1bfg2_86VMMRJkLyIuI2mLXOc6NrVwUkA8YaAvYAEALw_wcB

As for the "squeeze" clamp you need to squeeze and wiggle with quite a bit of force/pull to get those loose.

cas951 · 04-15-2019, 04:07 PM

Quote:

Originally Posted by Starter986

This isn't rocket science, I believe. I'm not understanding why anyone wouldn't just cut the bellows and pull it out. Then, get your hand in there and remove the clamp. Voila! Magic. An illusion?

I mean, a new one is going back in and with that handy blue-pull-clamp... done.

Might save some serious time. I know it did for me.

This is what I do. Makes the job so easy and the new AOS comes with one.

Newsguy · 04-15-2019, 10:29 AM

How about that 6mm bolt attaching the AOS? It's proving a little tough as you can get a ratchet on it but not keep enough pressure to keep the socket firmly on the bolt with one hand. I got the lower one loose, but that was because I could get a wrench on it.

Update: got it with the help of a 6-point deep well and long handle ratchet. Now having fun with the upper vacuum "squeeze" clamp. That special clamp tool is great for the lower one!

patssle · 04-15-2019, 02:00 PM

Get the right tool for the squeeze clamp and it's a whole lot easier.

KRAM36 · 04-15-2019, 02:17 PM

I just used a pair of big pliers, set it to clamp no further then what was need to squeeze the tabs and it popped right off for me.

maytag · 04-16-2019, 04:26 PM

Are you (OP) talking about the squeeze-tab ring/ clamp on the end of the short accordion hose, which then goes to the TB?
If so, yes, I agree.... sucks a$$. But a new hose is cheap. Break it off, be done with it.

Sent from my SM-G970U using Tapatalk

tommy583 · 04-16-2019, 04:50 PM

Or just take the hose off of the throttle body side. Then unbolt the AOS and take it out with the hose still attached. Then you can work on the other end of the hose out of the car.

neumaiek · 04-16-2019, 05:28 PM

Success!! I cleaned the fitting with WD40 and banged on it a little to losen any crap that accumulated over the years. Then got a pliers on the squeeze clamp and managed my other hand to get on the tube and press and wiggle outward. After a bit it slowly disengaged. YAY! No damage.

I was actually contemplating having to replace the whole breather tube and after looking at the schematics on the parts sheets on ********************************************.com decided that the Boxster design would allow for a not to bad replacement of the breather hose as I could get to all of it. But luckily not the case.

Next the bolts and removal (I am expecting to just yank it and take out the bottom of the bellows and clamp like a Neanderthal). Hopefully the installation is as advertised. Then it is on to cleaning out the intake and throttle body.

Thank you all for the great ideas as they did all make a difference. One thing though.. that remote spring clamp tool goes for >$20 at WalMart and other places want $140+. Good thing I don't need it!

KRAM36 · 04-16-2019, 05:55 PM

Good to hear. Like I posted, I used a pair of pliers also.

neumaiek · 04-17-2019, 12:38 PM

Good morning,

Well the new AOS went in like a beauty. I yanked it and the metal sleeve on the bellows stayed with the bellows so I had to tap that back in.

Cleaned the throttle body and it leaked a lot when I removed the cross tube. Now I was concerned. When I removed the forward cross tube HOLLY CRAP!!! A piece of the engine came out!

Long story short.... this engine is done. And I was always expecting the IMS to cause its death. At this point something on the passenger side broke enough to cause the anti-freeze to enter the system. Cracked head from a broken valve I suspect from what it sounds like and the amount of white smoke.

Again, thanks for all the successful tips that now makes me confident of replacing ignition coils; spark plugs, AOS; cleaning intake throttle body; cleaning cross tubes, etc.

Next task is disposing of car. Been a great 90k!

Sadly,
Kurt