I have a 2000 Boxster S 3.2 w/ factory single row bearing and am currently stalled in my install of the Pelican IMS replacement kit using LN toolkit (my order id #1339174643-508). I followed the current web installation guide instructions for project #14 (
Pelican Technical Article: Boxster Intermediate Shaft Bearing Replacement and Upgrade (IMS) - 986 Boxster (1997-04) - 987 Boxster (2005-06)) to the letter and had no issues until the step illustrated in fig. 109. We assembled the install tool, bearing w/ prepressed stud and the 12mm nut, with the nut lubed and hand-tightened with a deep socket and froze it overnight. We tapped it into the motor and then hit our snag: the nut WOULD NOT come off by any ordinary means (slotted screwdriver inserted through 12mm deep socket held by vise grips), meaning that the installation tool was stuck in the engine. I fabricated a long slotted bit for my hand impact driver that could reach thru the socket, and was finally able this afternoon to remove the nut after much despair and gnashing of teeth. When the tool was pulled off, it appears that the center stud had been pushed through and was not longer pressed into the bearing (see attached photo).
As you can see in my photo, the center stud is now just floating in the tube and is no longer attached to the inner race of the bearing. I may be able to use the installation tools to pull the stud back through and get it snug again in place, or I can remove the entire assembly and press it back together with a vise and repeat the entire process with the un- and re-installed bearing/stud assembly. I am not sure if that route is safe though, because of degradation of the bearing due to pulling it. If it is possible to get another one of the bearings by itself, that seems like safest course, although I'd like to get my car back on the road ASAP.
Additionally, the entire IMS shaft appears to be off-centered, cocked up and to the right at about 1 o'clock (see pics again). As I followed the Pelican instructions exactly, I removed the two rear tensioners and used set screws to secure the IMS sprocket, but did not lock out the motor at TDC, as the LN instructions dictate. I have since learned that this allowed some cam chain tension to remain and that the front side tensioner paddle must have pushed the IMS shaft off at an angle. I don't know if installing the cover will push the tube back to the center.
I've already given myself the deserved 40 lashes for not locking out at TDC, but will say that I would've done this had I known to -- my kit's instructions did not mention it at all.
So, do you think it's safe to leave the bearing in place and try to get the stud back in, or do I need to go back to square one? And what about the IMS tube being off-center? I know that this has happened to other guys before me and it seemed to work out, but I am feeling pretty nervous about the whole thing.
Thanks for your feedback!
