Oil Sender Boot

[Zirconocene]

Hi all-

As part of some larger work on motor mounts, OPG, and a steering rack refurb, one of the WYAIT things is dealing with a very brittle oil sender terminal boot. Mine broke when I unplugged the connector and full removal involved cracking the thing off the wire/sheathing.

The nice ones with the ears are a little hard to come by, and the one I ordered from one of the standard vendors didn't suit, so I found some alternatives.

Essentially, these are all 90 degree JPT connector boots. What I liked about them is that I didn't have to cut and resplice the sensor wire to fit it through the boot. I bought 3 options, not sure which one would really work. I went with the longest of the boots but they would all work.

Below you can see the part that I bought, on the left. Try as I might there was no way I was getting the connector through that little hole in the end of the boot. All the others have a much larger opening which allows for the connector to be fed through with no cutting or splicing.

Cheers

20220709_102626.jpg (3.69 MiB) Viewed 725 times

20220709_102555.jpg (3.39 MiB) Viewed 725 times

20220709_102502.jpg (2.91 MiB) Viewed 725 times

20220709_102448.jpg (3.45 MiB) Viewed 725 times

20220709_081702.jpg (3.52 MiB) Viewed 725 times

[dr bob]

Thanks for that tip!

The boot I ID'd for Roger way-back-when matches the original but with slightly smaller "ear flaps". It's a good match except for that, and unless you have the new and the old side by side you wouldn't know a difference. The JPT boots I have are too big both on the cable and the "pin" end, but mine are straight and for a two-pin connector. Maybe the one you have is a better match. If you can share some details and a source/link it might be a good option for me next time I have things apart. The wire on mine is half-crispy and in need of replacement sometime soon.

I made a temp fix with a little heat shrink over the terminal last time the oil sump was off, and will likely use the same when I replace the FOE KS-2 harness with new.

For those playing along at home, we are talking about the insulating boot over the 90º connection to the oil level switch on the front left corner of the oil sump. The circuit is switch-to-ground, so the purpose of the boot is more for keeping the connection clean than for electrical insulation.

[DonaldS4]

Kind of the same problem I had last year when I replaced my fuel pump and filter. Those rubber boots get hard and brittle, and I replaced them with similar boots that Roger had for $5 each. A simple fix, but I did have to cut the old terminal wires off, as mine were not coming through the small hole.
Imagine a piece of rubber only lasting 30 years?

[Tom]

Kind of the same problem I had last year when I replaced my fuel pump and filter. Those rubber boots get hard and brittle, and I replaced them with similar boots that Roger had for $5 each. A simple fix, but I did have to cut the old terminal wires off, as mine were not coming through the small hole.
Imagine a piece of rubber only lasting 30 years?

Are the original boots NLA? What is/was the part number?

[Tom]

@Kroonwireharness does a lot of reproduction rubber boots/grommets. Everything I've seen from them is virtually perfect. Not entirely sure if this is something they produced or found, but they offer this:

https://www.kroonwireharnesses.com/pors ... -928-kro27

[dr bob]

Kind of the same problem I had last year when I replaced my fuel pump and filter. Those rubber boots get hard and brittle, and I replaced them with similar boots that Roger had for $5 each. A simple fix, but I did have to cut the old terminal wires off, as mine were not coming through the small hole.
Imagine a piece of rubber only lasting 30 years?

Are the original boots NLA? What is/was the part number?

Porsche doesn't list a part number for the boot alone, unfortunately. We identified the same boot on a M-B harness, then searched for that in the aftermarket/replica/replacement community for those cars.

There's a large amount of engineering incest among the German brands. Engineers bounce around for project work. Plus Bosch makes a lot of parts that don't require reinvention. The pieces Roger sells are good, and except for the size of the wings they are a perfect replica of what came on the car originally.

That Kroon part looks great, and has the larger wings that make it a perfect replacement for the perfectionist. The funny part of all this is that Porsche (and M-B and GM and BMW) shopped for the cheapest parts that met the design duty. 35 Years later we obsess over finding an exact match to what was readily available at the time, when there are certainly more modern pieces that are better, cheaper, and available.