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ddruker · 03-17-2021, 09:08 AM

I spent an hour or so yesterday removing the old rear main seal and the IMS bearing cover, and cleaning up the gunk that had accumulated on the transmission case. I also spent another hour cleaning all of the parts I had removed - tons of grunge from 20 years on the road.

Other "while I'm in there" jobs I did yesterday:

- I cleaned out and re-greased the axle CV joints
- I removed and replaced both transmission mount capsules (new part is Rein AVT0307P, you need two)
- I evaluated the drivers-side transmission output shaft. It was covered in gunk, but after a thorough cleaning it looks like it was probably not leaking after all.

Notes on the RMS and IMS:

It took several attempts drilling a small hole into the old rear main seal and using a small screw to pull the old seal out - it was stuck in there pretty good.

It probably took 20 minutes to remove the old IMS cover. I went very very slowly levering back and forth on both sides, using pieces of wood to level against to protect the engine block. It was a tedious process.

I did find a small nick on the outside edge of the crankshaft bore which I smoothed with 1000 grit sandpaper.

I also noted that the crankshaft bore is a tiny bit uneven, creating a small raised ridge, where the two halves of the engine case come together. I'm not going to mess with this.

I will do a more thorough cleaning of all mating surfaces with acetone or lacquer thinner once the new parts to finish up the job arrive.

More notes:

It was a bit difficult to get the small pieces of cooling hose off to disconnect the transmission from the cooling system. They were really stuck! I found that lifting the end of the hose and spraying in some silicon lubricant helped a ton. I'm planning to replace these segments when reinstalling - they are standard 18mm ID, 25mm OD radiator hose you can find on the internet and cut to length. Cohline is one good brand.

Mark the transmission to engine bolts when you remove them to make it easier to remember which goes in which hole - I marked them one to seven on their heads with a sharpie.

You will need to replace most of the last step bolts when doing this procedure - they are one time use fasteners.

- 8 flex plate to crankshaft mounting bolts - 99907309101 - these are different shorter bolts for the tip than for a manual transmission
- 4 engine casing bolts - 99938500401
- 3 new IMS cover bolts and and a new IMS cover nut which come with the LN Engineering Kit

You also need to obtain the following specialty chemical items - I bought on Amazon

- Loctite 29031 wicking green threadlock for the new IMS cover nut
- Elring Curil T sealing compound for the IMS bolts

I now have at least 10 labeled zip lock bags of parts I've removed - one bag for each step in the process.

Make sure you have plenty of blue locktite on hand for the re-assembly process.

I also bought a paint pen to mark the final location of the various fasteners.

Knock on wood so far everything is going well.

03-17-2021, 09:08 AM	#13
ddruker Registered User Join Date: Jul 2018 Location: Palo Alto, California Posts: 59	I spent an hour or so yesterday removing the old rear main seal and the IMS bearing cover, and cleaning up the gunk that had accumulated on the transmission case. I also spent another hour cleaning all of the parts I had removed - tons of grunge from 20 years on the road. Other "while I'm in there" jobs I did yesterday: - I cleaned out and re-greased the axle CV joints - I removed and replaced both transmission mount capsules (new part is Rein AVT0307P, you need two) - I evaluated the drivers-side transmission output shaft. It was covered in gunk, but after a thorough cleaning it looks like it was probably not leaking after all. Notes on the RMS and IMS: It took several attempts drilling a small hole into the old rear main seal and using a small screw to pull the old seal out - it was stuck in there pretty good. It probably took 20 minutes to remove the old IMS cover. I went very very slowly levering back and forth on both sides, using pieces of wood to level against to protect the engine block. It was a tedious process. I did find a small nick on the outside edge of the crankshaft bore which I smoothed with 1000 grit sandpaper. I also noted that the crankshaft bore is a tiny bit uneven, creating a small raised ridge, where the two halves of the engine case come together. I'm not going to mess with this. I will do a more thorough cleaning of all mating surfaces with acetone or lacquer thinner once the new parts to finish up the job arrive. More notes: It was a bit difficult to get the small pieces of cooling hose off to disconnect the transmission from the cooling system. They were really stuck! I found that lifting the end of the hose and spraying in some silicon lubricant helped a ton. I'm planning to replace these segments when reinstalling - they are standard 18mm ID, 25mm OD radiator hose you can find on the internet and cut to length. Cohline is one good brand. Mark the transmission to engine bolts when you remove them to make it easier to remember which goes in which hole - I marked them one to seven on their heads with a sharpie. You will need to replace most of the last step bolts when doing this procedure - they are one time use fasteners. - 8 flex plate to crankshaft mounting bolts - 99907309101 - these are different shorter bolts for the tip than for a manual transmission - 4 engine casing bolts - 99938500401 - 3 new IMS cover bolts and and a new IMS cover nut which come with the LN Engineering Kit You also need to obtain the following specialty chemical items - I bought on Amazon - Loctite 29031 wicking green threadlock for the new IMS cover nut - Elring Curil T sealing compound for the IMS bolts I now have at least 10 labeled zip lock bags of parts I've removed - one bag for each step in the process. Make sure you have plenty of blue locktite on hand for the re-assembly process. I also bought a paint pen to mark the final location of the various fasteners. Knock on wood so far everything is going well. Last edited by ddruker; 03-17-2021 at 09:41 AM.