Noisy Idlers, ABS sensor woes, and Washer fluid leaks

Earlier last year I noticed wiper washer fluid was leaking all under the Jeep. The typical fix for this is replacing the washer fluid pump strainer which I did. Unfortunately this didn't really fix the problem so I decided to complete just replace the whole washer fluid bottle since the pump itself wasn't leaking. This is someone annoying to replace since it comes with a full tray assembly for where the ECU sits so I had SJF take on this project. Turns out the existing bottle itself was fine and my main issue was with the hose but whatever, I already had the new part so why not put it in anyway.

new wiper washer bottle assembly

Since the Jeep was going to be with SJF for a while anyway, I figured i'd address a few other things like replacing the 4 ABS sensors since I would get the traction control light go on when driving on the highway for extended periods of time. This is typically caused by a bad sensor so got some new OEM ones to replace them. Turns out the rear rear abs wire had gotten damaged at some point and that was the main source of it but glad to have these sensors replaced anyway. I also had the crank sensor replaced which a very typical item to go bad on these vehicles. It's 10 years old now and I don't want to get stranded somewhere because of a bad sensor so a new OEM one went in as well.

New hub assembly

While the ABS sensors were getting replaced, the right front hub was showing some play so that got replaced. There were also some wear issues on one of the brake caliper bracket so had both front brake calipers and brackets completely replaced as they were pretty cheap anyway. 

New front brake caliper

New front brake caliper

The front bumper stops were also completely worn out and falling apart so those were both replaced with fresh new ones. I had this whining supercharger like noise too from the engine when it was cold. At least one of the idler pulleys was not happy at all so I got them all replaced along with the tensioner and the main drive belt and now it's back to being silent. 

Maintenance Update:

Mileage: 84,485

- New wiper washer fluid tank assembly

- New idler pulleys

- New belt tensioner

- New main drive belt

- New front bump stops

- New front calipers

- Brake fluid flush

- New front right wheel hub

- New right rear ABS sensors wire 

- New ABS sensors all around

- New crank sensor

JCW Suspension

Ever since I got the Mini, I wanted to do an OEM+ upgrade by doing a JCW conversion since they don’t make a 4-door JCW. I already completed most of that conversion shortly after buying the car and even sourced the JCW suspension new but just didn’t get the opportunity to install it to complete the transformation. After a few years of procrastination I decided it was time so I dropped it off with SJF so he could complete the install.

JCW suspension

The JCW coilovers are height adjustable but have a fixed valving and are made by KW. Since the car has almost 85k miles, I figured I’d also get brand new hardware, top hats, etc for the install to just freshen things up since putting those old components with new suspension seemed like the wrong thing to do. 

New front shocks and springs

New rear shocks

New top hats and associated hardware

The overall installation went pretty smoothly and I had the ride height set to just a little under factory height since it’s winter and the suspension settled maybe around 0.25-0.5” after sittting around before alignment. 

Front suspension installed

Rear suspension installed

New ride height

The car feels really amazing to drive. The ride is a bit more firm but very well controlled just as you’d expect from a KW tuned suspension setup. I’m definitely very happy with the upgrade and I’m glad that the JCW conversion is finally complete.

While the car was there I also had SJF flush the brake fluid since that was due.

Maintenance Update:

Mileage: 84,996

- New JCW suspension (made by KW) all around

- All new suspension bolts, top hats, etc for the suspension

- Motul RBF600 brake fluid

New Seat Foam for the 944

The interior on the 944 is actually really clean and original. The only thing after 35 years is that the driver side seat bolster flattened over the years so I wanted to actually fix this to make things 100%. Unfortunately finding brand new OEM seat foam is difficult, if not near impossible, so I bought some new seat bottom foam from Design911 in the UK.

Seat out of car with new foam next to it

New foam

The only problem with the new foam is that it’s a bit generic for the standard seat so it’s not a direct replacement. It doesn’t have the appropriate cut outs for the power seat controls nor and doesn’t match all the contours needed to slot in to the seat frame.

Removing the seat cover and cushion from frame

New seat foam vs very old one

I spent several hours cutting and trimming the new foam to match the old foam then recovered and attached everything back to the seat frame. It was frankly way more work than I thought it’d be but not only does the bolster look better, the fresh foam makes the seat feel much better and supportive.

All the foam trimmings

Seat bottom frame

Everything put back together