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I know this has been written up before, but my '99 finally came down with the auto-honk annoyance. Hard stops caused an embarrassing honk of the horn.

I used the ZipZapDIY's youtube - [video]http://www.youtube.com/watch?v=2WqhZaaXL2I&list=PLk4xZ7Vzp09-ooIPEGFuePGIBOAEZkpIW&feature=share[/video]

I bought these washers for $2.27 at Home Depot:


The original busshings looked like this:


After inserting the o-rings, they looked like this:



Now, the horn now only hons when I want it to! smiling smiley
Great video... and timely. 2000 Boxster... same failure.
I choose to disconnect the battery until I understood how to work safely with the air bag.

After disconnecting the battery and waiting 2 hours (?)... is it safe to work around the air bag or is there any chance of activation?

thanks. I'd rather work under my car than around an air bag and don't know if this a legitimate concern (nervousness), appreciate the insight.
... just disconnect the negative side of the battery and wait 15 minutes.
Many people disconnect the airbag with the battery fully connected and nothing happens, but by waiting 15 minutes after battery disconnection there won't be any power to trigger it by accident.
Happy Boxstering,
Pedro

Pedro Bonilla
1998 Boxster 986 - 299,000+ miles: [www.PedrosGarage.com]

PCA National Club Racing Scrutineer - PCA National HPDE Instructor - PCA Technical Committee (Boxster/Cayman)



Racecar spelled backwards is Racecar

"Racing is life. Anything before or after is just waiting" ... Steve McQueen as Michael Delaney in "LeMans"

"If you wait, all that happens is that you get older"... Mario Andretti

"Being second is to be the first of the ones who lose" ... Ayrton Senna

Minus 40 degrees... Is that Fahrenheit or Celsius?
Edited 1 time(s). Last edit at 05/27/2014 03:04PM by Laz. (view changes)
If you disconnect the ground strap, her is no complete circuit, and nothing to generate an ignition signal for the airbag.

Electrons must flow from the positive terminal, though the device, and to ground. Or, if you happen to be a physicist not an EE, the opposite direction :-)

Grant

Grant

gee-lenahan-at-gee-mail-dot-com
A two-fold question actually. I would think disconnecting the positive ("hot," yes?) side is more effective/safer, if only one lead is to be disconnected.
The terms "hot" and "positive" are just mental constructs. If either lead to the battery is disconnected, there is an open circuit...don't think one is any "safer" than the other.

HOWEVER, we always think it is BETTER to disconnect the NEGATIVE terminal FIRST because of how a car is grounded:

IF the NEG terminal is still connected to the battery while undoing the POS terminal AND the metal wrench touch something metal on the car, current could flow across the wrench...which would be quite bad.
However, the same is not true if the POS is attached and you touch the NEG terminal with a wrench to any metal parts of the car.

Happy to have folks poke holes in our "rule of thumb."



Edited 3 time(s). Last edit at 05/28/2014 03:58PM by RainyDayGarage. (view changes)
i agree that disconnecting the ground terminal is safer because it can't accidentally hit someting and short to...itself

Plus, if any charge is stored in, say, a capacitor, disconnecting the ground zeros that potential as well.

Grant

Grant

gee-lenahan-at-gee-mail-dot-com
so even with no power source, it is *possible* that something *could* set it off - electrostatics, etc.

but its very, very unlikely with the power disconnected.

That said, it is generally advisable to store them, in my opinion, face UP so that if it was to explode, the case would not become a projectile.

I've pulled mine > 10 times.

Shame about my nose.

Grant

Grant

gee-lenahan-at-gee-mail-dot-com
As I have said many times on this board, the signal that triggers the airbag is not a simple ground/power; it is a digital handshake, which is impossible to happen without the SRS deliberately trying to activate the airbag. You can send random electrical signals into the airbag plug for a million years and it will never trigger.
the air bag has just 2 wires to its initiator.

While there is some processing to arrive at a decision to deploy the air bag, the air bag initiator has no smarts. It is like a detonator for an explosive charge. Placing an airbag the wrong way down on a bench can have a static spark jump across the gap between the air bag electrical connector and the bench and set off the air bag.
In any case, what you're saying makes no sense.

It would be downright negligence for any company to design an airbag that way. Spurious electrical signals can happen and if what's at stake is the driver's life, designers will never risk that.
Quote
Boxsterra
In any case, what you're saying makes no sense.

It would be downright negligence for any company to design an airbag that way. Spurious electrical signals can happen and if what's at stake is the driver's life, designers will never risk that.

deployment risk, though there are exceptions. In one case there was one deployed that was triggered from a hand held radio suspended by a strap from the rear view mirror swinging back and forth by the dash.

BTW, there are a number of things that are at risk of spurious voltage signals, though a spurious signal does not trigger an airbag, but can still cause considerable havoc and damage. The various sensors and DME and other controllers in the car are all at risk from spurious electrical signals and yet we seldom hear/read about anyone having to deal with the aftereffects of a spurious electrical signal.

For various reasons these just do not happen.

The actual trigger signal is a voltage level to the igniter. What triggers this signal can be a processor that decides deployment is necessary and what level of deployment is called for.

It is like a detonator at an explosive charge. It takes some work to initiate the signal to set off the detonator and thus the explosive charge but the signal is just a voltage level.

We are talking about air bags that are removed from their natural environment and in this case are at risk of a static discharge that can trigger the deployment of the air bag.

Whether you want to observe proper safety precautions when around airbags or other pyro-technical safety devices is up to you but the factory service manuals are quite clear on how air bags and other pyro-technical safety devices are to be handled/treated.

Below is a cut/paste from the factory manual.

WARNING
Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 1) Please observe the following points:
• The airbag units are pyrotechnical items in hazard class T 1!
• Handling, transport and storage of these units must conform to the explosives legislation!
• The listed statutory requirements refer to the Federal Republic of Germany!
• The relevant valid regulations must be observed in all other countries!
• The commencement of work with pyrotechnical items must be reported 14 days in advance to the
Trade Supervisory Office (responsible authority)!
• Airbag units may only be dispatched in transport packaging officially approved for that purpose!
• Airbag units may not be transported with other hazardous goods!
• Internally, they must always be transported in the luggage compartment or cargo hold of a vehicle
using the above−mentioned transport packaging!
• They must not be transported in the passenger's compartment!
• Airbag units must be stored in accordance with the second ordinance of the explosives legislation!
• This ordinance stipulates that small quantities of materials and objects may be stored at certain
locations without special storage approval!
• According to the Explosives Storage Directive of August 1997, these quantities are max. 10 kg (net)
in a work room and max. 100 kg (net) in a storage room in the case of Class T 1 pyrotechnical items!
WARNING
Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 2) Please observe the following points:
• Airbag units must be kept in a locked place!
• When storing airbag units, ensure that the airbag opening faces upwards (risk of injury caused by
inflation of the airbag units in the event of accidental ignition)!
• Airbag units must be stored in a dry place and must not be stored together with other hazardous goods
(varnishes, etc.)!
• Loose airbag units, referred to as airbag modules below, or airbag modules installed in a loose
steering wheel must never become the actual (physical) property of the customer!
• The possession of loose airbag modules not installed in the vehicle is not permissible in the private
sector!
• Airbag modules may become the property of the customer only when installed in the vehicle!

DANGER
Danger of injury through malfunction of airbag system.
• Never drive with an unlocked triggering unit − airbag.
• As long as the airbag triggering unit is not locked, the warning light lights up continuously.
The triggering unit is locked with the Porsche System Tester.
WARNING
Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following point:
• Inspection and assembly work may only be carried out by specialist staff
Before working on the airbag system and also when working on neighbouring parts where there is a risk because live parts are close to the airbag system, always implement the following safety measures:
1. Remove ignition key.
2. Disconnect and cover the negative terminal of the battery.
WARNING
Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 1) Please observe the following points:
• Inspection and assembly work may only be carried out by specialist staff!
• After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar
tools may not be started until after a waiting period of 1 minute! This is necessary in order to interrupt
the power supply to the airbag system and to ensure it is not triggered accidentally!
• This is necessary in order to interrupt the power supply to the airbag system and to ensure it is not
triggered accidentally!
• Airbag units must be fitted immediately after being removed from their storage location!
• On no account may airbag units be left lying around unsupervised!
• If work is interrupted, airbag units must immediately be locked away again!
• Airbag units must not come into contact with grease, oil, cleaning agents or similar substances!
• Airbag units may not be exposed to temperatures above 90 °C!
• Airbag units and control units which have fallen from a low height may no longer be installed!
• No additional linings, stickers or similar may be attached to the steering wheel in the vicinity of the
passenger's airbag and side airbag!
• No changes may be made to the wiring and to the components of the airbag system!
• The battery must always be disconnected before starting straightening and welding work with an
electrical welding unit!
• Electrostatic charge: in general, suitable work clothing and footwear are to be worn. => Materials
• Never connect airbag units to electrical power sources not in accordance with regulations (danger of
immediate ignition). Only use testers prescribed by the manufacturer. ’ 0, 6901 Airbag diagnosis .
Assembly and adjustment work 310
einordnung
WARNING
Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 2) Please observe the following points:
• The control module must be removed in advance if you have to perform welding in the immediate vicinity of the control module!
• Airbag components may not be repaired!
• Airbag components must always be replaced!
• Wash your hands after touching triggered airbag units!
top of page
Handling airbag and belt tensioner Dangers for persons and the environment
Note
• Injury caused by incorrect triggering of the installed unit.
• Injury caused by spinning away e.g. of the entire unit.
• Burns caused by touching the hot surfaces of a triggered unit.
• Damage to hearing due to the explosion when gas is released.
• Irritation caused by breathing in explosive dust, especially in older models.
• Irritation due to skin and eye contact with slag produced by the explosion, especially in older models. • Airbag/belt tensioner components should neither be opened or repaired; always use only new parts.
• Injury caused by incorrect triggering due to manipulation of the short circuit bridge.
Protective measures and rules of behaviour
Note
• Assembly work only by trained staff.
• Carry out tests only with the Porsche System Tester diagnostic module; do not use test lamps,
voltmeters or ohmmeters.
Handling airbag and belt tensioner 311
einordnung
• Do not bring into contact with grease, solvents or cleaning agents.
• Do not expose to temperatures above 100°C.
• Keep the unfolding area of the airbag clear; e.g. do not hang test devices over the steering wheel. When carrying, hold the airbag with the blow−out direction facing away from the body. Store the unit with the airbag facing upwards.
• Electrostatic charge: in general, suitable work clothing and footwear are to be worn. => Materials
• Do not remove the short−circuit spring of the plug contacts.
• Never connect airbag units to electrical power sources not in accordance with regulations (danger of immediate ignition). Only use testers prescribed by the manufacturer. ’ 0, 6901 Airbag diagnosis .
• During installation/removal or work on the vehicle involving shocks: switch off ignition, disconnect and cover the negative terminal of the battery, wait 1 minute and only then disconnect the plug connection.
• Transport: in transport packaging. Forbidden in passenger compartment!
• Storage in the workshop: max. 10 kg (=> 100 driver's or 50 passenger's airbags); security against
theft!
• The installation of the airbag/belt tensioner unit must be carried out immediately after removal from the transport container.
• If work is interrupted, the airbag/belt tensioner unit must be stored in the transport container again.
• Leaving the belt tensioner unit unsupervised is not permitted.
Behaviour in cases of malfunction or danger
Note
• Protect against flames and heat.
• In case of fire, inform the fire brigade on arrival about the units present.
• Do not install mechanically damaged units or units that have fallen from a low height.
• Always replace units that are mechanically damaged (bulges, cracks).
• Because of the irritating combustion residues, only handle triggered airbags with protective gloves and goggles.
• In the case of contact with combustion residues, wash the affected skin with soap and water.
Protective measures and rules of behaviour 312
einordnung
• In the case of eye contact, wash the eyes with water.
and i quote:
grant - 7 years ago
"Transport: in transport packaging. Forbidden in passenger compartment!"
Hmmm - isn't this designed to be in the passenger compartment and aimed at my head?

I'm beginning to question that list :-)

Grant

Grant

gee-lenahan-at-gee-mail-dot-com
A digital signal does not trigger a pyrotechnic device. Some form of spark or fire does. Maybe that spark or fire is triggered by a stored charge and initiated by a code, but we can;t run a low-voltage 10101111001 to something and expect it to blow up.

From what you say, nonetheless, i'll surmise that there's another level of protection between static and boom, which makes m feel much better.

Grant

Grant

gee-lenahan-at-gee-mail-dot-com
I appreciate the video... everything went fine. Unfortunately the airbag disconnected as I reached under to install the underside o-rings. Clipped it back in place. Horn now works when it should :^)

Now who's replaced the rear trunk release cable?...
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