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Old 01-17-2013, 03:15 AM   #13
Eric G
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Join Date: Dec 2011
Location: Pacific Northwest
Posts: 793
Garage
Starting from the front of the car going toward the tail end:

Drivers side radiator: Small leak on at the mounting lug, symptoms occasional fluid by tire on hot days. Seems the bumper was tapped and cracked the mount.
Grill guards on radiator intake Protection from debris build up in radiators.
Canister Purge valve: Code from Durametric
Horn Old horn was to quite, replaced with Stebulis air horn
Front suspension and rear complete suspension and sway bar bushings Struts were completely shot with no dampening, bushing were worn and cracked.
Wheel bearings Replaced all four wheel bearings with a tool that allowed the job to be completed in only 5 hours for all four wheels!
Rotors and pads Worn to maximum extent possible.
Water pump and low temp thermostat: No symptoms, just an upgrade. Old components were working
Fan Belt:Replaced older belt
AOSSaw increased oil build up in the throttle body and small puffs of smoke in the morning.
Spark plugs/tube/coils Plugs were clean but replaced with new, tubes showed signs of moderate to severe leaks, coils replaced as preventative measure.
Rear Main Seal (RMS) Seal had failed and was leaking
IMS No visible leakage, but bearing was in stage 1 failure in that there was no grease and bearing was filled with engine oil.
All three cam chain tensioners Under harmonic analysis there was a large signal to noise ratio, when removed all three showed signs of internal spring failure when compared to new tensioners.
Clutch, pressure plate, throughout bearing, dual mass flywheel While there were no symptoms, they were all roasted and were close to failure.
Super clutch kit from Pelican This is offered from Pelican and replaced all the other parts associated with the clutch components
Clutch Master and Slave cylinders Replaced as part of a preventative measure
Clutch fluid line and connector This is required with upgrading the slave cylinder (will add about $320 to add these two parts)
CV joints and all boots and axle nuts Preventative replacement.
Transmission and Engine mounts All were shot but showed no signs of failure (I may not have recognized the signs???)
Oil filter housing Upgrading a 14 year old component
Radiator Reservoir While there was no leakage the tank was severely aged and showed spiderwebs cracks.
New JDM seats with lowered mounting bracket Considered to be an upgrade from OEM seats providing better seating position.
JDM performance steering wheel Personal choice allowing better driving position
Gahh new top (soft window) Replacing older top which is beginning to show cracking in window.
Conversion of top Converted top to manual while retaining power clam shell operation (personal choice).
Sirius radio Upgraded for personal choice
LCD control panel for heater/AC Replaced due to failure of switches and LCD (nice replacement for $57 verses the $750 OEM replacement cost!
Various pieces and parts as well as tools to aide in the work process
Alignment Once my wheels are back from powder coating she will get her patas set straight so she runs true.


Here is a list of the parts from Pelican:

Cam chain tensioner 900-123-147-30-OEM Sealing Ring, 27 X 32, each
Cam chain tensioner 900-380-019-02-M100 HEX NUT M8 X 1
Cam chain tensioner 996-105-017-02-M100 SHAFT BASE
Cam chain tensioner 996-105-180-57-OEM Chain Tensioner, For Intermediate Shaft
Cam chain tensioner 996-105-186-01-OEM Chain Tensioner, For Cylinders 1-3
Cam chain tensioner 996-105-188-01-OEM Chain Tensioner, For Cylinders 4-6
Cam chain tensioner 999-707-344-40-OEM O-ring, 18.77 X 1.78, Each
Clutch 012-141-180-B-M100 Guide Tube For Clutch Release
Clutch 012-141-719-E-M100 Release Bearing Lever, Boxster (1997-04), Each
Clutch 012-141-741-M100 Retaining Spring for Clutch Release Lever, 986 Boxster/Boxster S (1997-04)
Clutch 012-141-751-C-M100 Pivot Piece for Clutch Release Lever, 986 Boxster/Boxster S (1997-04)
Clutch 012-141-777-D-M100 Ball Pin for Clutch Release Lever, 986 Boxster/Boxster S (1997-04)
Clutch 034-105-313-A-M5040 Pilot Bearing, Boxster/Boxster S (1997-04), Each
Clutch 8E0-721-257-M-M5038 Clutch Slave Cylinder
Clutch 900-067-131-03-M260 Pressure Plate Bolt, 8 X 16 mm, 6 Per Car, 996 Carrera 2/4 (1999-04), Boxster/Boxster S (1997-04), Each
Clutch 996-423-171-06-M33 Clutch Master Cylinder, 996 Carrera 2/4 (1998-04), Boxster/Boxster S (1997-04), Each
Clutch 997-101-212-01-M17 Flywheel Seal, 996 Carrera 2/4 (1999-04), Boxster/Boxster S (1997-04), Each
Clutch 999-073-092-02-M260 Flywheel Bolt - M10 x 50mm
Clutch 999-230-541-10-M100 Union for Clutch Fluid Pipe, Boxster (1997-04), Each
Clutch I3020-377426-OES Clutch Fluid Hose, Boxster, From Chassis Number 98XS620221 To Chassis Number 98XU624362 1999, Each
Clutch N-903-542-01-M100 RUBBER O-RING
Cooling system 996-106-011-56-M244 Water Pump with Composite Impeller (requires one 996-106-340-54-M30 gasket)
Cooling system 996-106-013-59-M902 Water Thermostat, Low Temperature (begins opening at 160 deg F) with Cover and Gasket
Cooling system 996-106-147-08-OEM Coolant Expansion Tank, Boxster/Boxster S (1997-04), Each
Cooling system 996-106-340-54-M30 Water Pump Gasket, 996 (1999-2004), Boxster/Boxster S (1997-2004)
Engine components 016-311-113-C-M213 Main Shaft Seal for Manual Transmission
Engine components 987-375-023-05-M100 Engine Mount, One Per Car, Each
Engine components 996-105-325-52-M100 Spark Plug Tube (Note: Does Not Include O-Rings)
Engine components 996-107-023-04-M100 Oil Separator, Boxster (1997-02) 1997-99 models up to 1999 engine# 65X 01419 also use (1) 996-107-145-06-M100 vent line and (1) 999-707-446-40-M100 o-ring, Boxster S (2000-02)
Engine components 996-107-225-60-M45 Hengst (OEM) Oil Filter Insert (Filter Cartridge and Seal)
Engine components 997-602-107-00-M47 Ignition Coil (sold per each, 6 required)
Engine components 999-512-630-00-M100 Oil Separator Hose Clamp, Lower (35 X 12)
Engine components 999-707-215-40-M17 Outer Spark Plug Tube O-Ring, 27.94 X 5.33 (6 Per Car) Boxster/Boxster S (1997-2004), Each
Engine components 999-701-789-40-OEM Seal for Air Oil Separator (Inside Oil Sump), Boxster/Boxster S (1997-04), Each
Engine components OEM-99610715006 Genuine Porsche Part: OIL FILLING PIPE
Engine components 996-104-215-54-M100 Camshaft End Plug 6 Per Car, 996 Carrera 2/4 1999-04, Boxster/Boxster S 1997-04, Each
Engine components 900-377-011-01-OEM M10 hex nut, each
Engine components 999-072-008-09-OEM STUD M 10 X 30, each
Engine components 999-218-088-09-OEM 999-072-008-09-OEM
Engine components 999-707-343-41-M17 Inner Spark Plug Tube O-Ring, 25.07 X 2.62 (6 Per Car) Boxster/Boxster S (1997-2004)
Steering 996-347-131-04-M80 Outer Tie Rod End (sold per each, 2 per car), 996/996 Turbo (1999-2004), Boxster/Boxster S (1997-04)
Steering 996-347-191-04-OEM Tie Rod/Steering Rack Boot, for original rack #996-347-011-06 or #996-347-011-07 (2 Per Car, sold individually)
Suspension 900-380-005-01-OEM Rear Shock Absorber Mounting Nut, For Securing Mount to Chassis, 6 Per Car, Boxster/Boxster S (1997-2004), Each
Suspension 900-380-012-01-OEM Shock Top Nut, M14 x 1.5
Suspension 986-331-043-07-M80 Control Arm Link (Track Arm), Rear Suspension, Left and Right, each, Boxster/Boxster S (1997-04)
Suspension 987-333-059-00-OEM Rear Shock Absorber Mount, 2 Per Car, Boxster/Boxster S (1997-04), Each
Suspension 996-333-792-24-OEM Rear Sway Bar Bushing, Stock Rubber, 18.7 mm (sold per each, 2 required), 996 (1999-2004), Boxster (1999-03)
Suspension 996-333-792-25-OEM Rear Sway Bar Bushing, Stock Rubber, 19.8 mm (sold per each, 2 required), 996 (1999-2004), M 030 Boxster (1997-99)
Suspension 996-341-043-06-M80 Control Arm Link, Front/Rear Suspension - Front Lower, Left and Right, each, 911 Carrera 2/4 (1999-05), 911 Turbo (2001-05), Front - Boxster/Boxster S (1997-04)
Suspension 996-341-053-17-M80 Control Arm, Front/Rear Suspension - Lower, Left or Right
Suspension 996-343-069-04-M80 Front Sway Bar Droplink, left front: 996 (1999-2005); left front or left rear: Boxster/Boxster S (1997-2004)
Suspension 996-343-070-04-M80 Sway Bar Droplink (sold per each), right front 996 (1999-2005), right rear or right front Boxster/Boxster S (1997-2004)
Suspension 996-343-107-03-OEM Upper Shock Stop Plate (sold per each, 2 per shock), front 996/996 Turbo (1999-2004), front or rear Boxster/Boxster S (1997-2004)
Suspension 996-343-301-02-M58 Rubber Bump Stop (Bushing), Front Strut, 986 Boxster/Boxster S (1997-04), 987 Boxster/Boxster S (2005- ), Cayman/Cayman S, 996 Carrera/Carrera 4 (1999-05), 911 Turbo (2001-05, except GT2), 997 Carrera/Carrera S with M475 PASM (2005- )
Suspension 996-343-505-00-M737 Protection Boot for Front Shock Absorber Left/Right (2 Per Car)
Suspension 996-343-515-05-M100 Front Shock Absorber Mount, Lower Rubber Bushing, 2 Per Car, 996 Carrera 2 (1999-04), Boxster/Boxster S (1997-04), Each
Suspension 996-343-792-14-OEM Front Sway Bar Bushing, Stock Rubber (sold per each, 2 required), 996 (1999-2003)
Suspension 996-347-322-03-M80 Inner Tie Rod (sold per each, 2 per car), 996/996 Turbo (1999-2004), Boxster S (2000-04)
Suspension 997-331-045-04-M80 Control Arm Link, Rear Suspension - Rear Lower, Left and Right, each, 911 Carrera 2/4 (1999-05), 911 Turbo (2001-05), Boxster/Boxster S (1997-04)
Suspension 997-343-018-01-M69 Shock Absorber Mount, Front, Upper Plate (2 per car, sold individually)
Suspension 999-084-447-01-OEM Front Shock Absorber Mounting Nut, For Securing Mount to Chassis, 6 Per Car, 996 Carrera 2/4 (1999-04), 996 Turbo (2001-2004), Boxster/Boxster S (1997-2004), Each
Suspension OEM-98633328501 Sealing ring Brand: Genuine Porsche
Suspension OEM-98633330101 Genuine Porsche Part: SHOCK RUBBER BUFFER
Suspension OEM-98633350402 Compensating plate, 3,0 MM Brand: Genuine Porsche
Suspension OEM-98633350501 Genuine Porsche Part: SHOCK BELLOWS
Suspension OEM-98633350902 Genuine Porsche Part: SHOCK MOUNT RING
Suspension OEM-99634351100 Compensating plate, 3,0 MM Brand: Genuine Porsche
Suspension OEM-99634351101 Compensating plate, 6,5 MM Brand: Genuine Porsche
Suspension OEM-99634351300 Cone washer Brand: Genuine Porsche
Suspension OEM-99634351701EM0 Support ring Brand: Genuine Porsche
Tools & Misc 996-721-151-00-M100 Factory Tow Hook, 911 Carrera 2/4 (1995-04), 911 Turbo (2001-05), Boxster/Boxster S (1997-04), 924/924S/924 Turbo all, each
Tools & Misc PEL-TOL-P222 Magnetic Box V Wrench (17mm)
Tools & Misc PEL-TOL-ST0229 16mm XZN Triple Square (Tamper Proof) Drain Plug Removal Tool for 5-Speed Manual Transmission, 1/2 in drive, Boxster (1997-04)
Tools & Misc PEL-TOL-T136 Clutch Alignment Tool, (Spline count = 23; Pilot diameter = 14.9 mm; Spline diameter = 23.8 mm)
Tools & Misc SCHW-P-648 Fuel Line Pliers (adjustable), fits newer BMW, Audi/VW, Porsche
Tools & Misc PEL-IMS-1 Pelican M96 Intermediate Shaft Bearing (IMS) Retrofit Kit, for either Single or Dual Row IMS
Tools & Misc LN-106-08-13 LN Engineering Intermediate Shaft Bearing (IMS) Puller/Counterstay, for extraction of single or dual-row bearing intermediate shaft bearings safely. Includes: puller, driver, 5 chain and 3 chain engine cam locks, TDC lock pin, and broken stud easy-out.
Tools & Misc PEL-0100 European Power Bleeder Kit, Porsche All
Tools & Misc 005773-0-M84 17mm Transmission Drain Plug Removal Tool (3/8 inch drive)
Wheels & Axles 016-409-399-B-M5213 Seal for Differential Output Shaft (45 x 60 x 8 mm)
Wheels & Axles 900-041-013-01-OEM Circlip - CV Joint (sold per each, 2 per axle), Boxster (1997-2003), Expandable Oil Return Tube Circlip (for 2 piece tube, sold per each, 4 required), 911/911 Turbo (1974-89)
Wheels & Axles 911-332-257-00-M395 CV Boot Clamp, 73mm (sold per each), 911 (1985-89), 911 Carrera 4 front inner and rear (1989-98), 928 (1982-95), 911 Turbo (1991-94), 944S2/Turbo, 996 (1999-02), 996 Turbo rear (2001-05), Boxster (1997-02), Boxster S (2000-04), 987 Boxster/Boxster S (2005- )
Wheels & Axles 928-332-257-01-M395 Axle Boot Clamp (34 mm), 911 (1985-98), 928 (1982-95), 911 Turbo (1991-94), 944S2/Turbo, 996 (1999-02), 996 Turbo rear (2001-05), Boxster (1997-02), Boxster S (2000-04), 987 Boxster/Boxster S (2005- )
Wheels & Axles 928-332-293-02-M60 CV Joint Boot, Inner or Outer (sold per each)
Wheels & Axles 951-332-901-00-M60 CV Joint Kit w/boot (25 splines), 944S2/968 All, 944 Turbo from 88, Boxster (1997-02)
Wheels & Axles 964-332-267-01-OEM CV Joint Splined End Cap
Wheels & Axles 996-332-257-00-M395 CLIP
Wheels & Axles 996-332-957-00-M395 Axle Boot Clamp (70.8 - 74 mm), Rear Inner/Outer
Wheels & Axles 999-053-041-04-M34 Wheel Bearing
Wheels & Axles 999-084-641-01-M100 Hub Tension Flange Nut, M22 x 1.5, front or rear (sold per each)

Total cost...just under $8000.00
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Last edited by Eric G; 01-17-2013 at 06:10 PM.
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