Replacing the IMS
 

Tonight started to dig for that IMS, exhaust brackets loose. First fatality, cracked taillight. Will do more in the morning.

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OK... I'll ask.

How did you break your tail light????? :eek:

Pulling the bumper cover off

With WD-40 RUST RELEASE, and 15" channel-locks, exhaust off in 30 minutes.

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Sorry to hear that as pulling the muffler with it on is simple. On the plus side, replacement shouldn't be too hard and is wayyy cheaper than a paint boo boo.

Why not just leave the bracket attached to the muffler and undo the bolts on the back of the gearbox. Looks like you unbolted the bracket from the muffler side on top and left the hanger attached to the gearbox. That's how to get around needing access to the very top of the muffler requiring the bumper to be pulled.

If you can't get those top two without bumper removal don't ever consider becoming a mechanic as these two bolts are duck effing soup compared to many other car access situations.

Car has 130,000 miles on it and it has never been opened up, a lot of the nuts and bolts are way stuck. I would of done things as suggested, but had to make do.

The WD-40 RUST RELEASE unfroze most in 5 min, the rest may take a little heat from Mr Smoke Wrench

I didn't remove my bumper to do the IMS. Not necessary. Just sayin'

Steve

Removing the 10 bolts of the aluminum pan,

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Undoing the anti-sway bars,

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Use pry bar to get apart,

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Pull the aluminum pan to the back of the car, it takes a medium tug.

Undoing the CV bolts, use a brand new torks socket , this will give the best bite into the head of the bolt,

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Run an exstention to the outside of the car,

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Use a hand impact driver, hit 4 or 5 times to loosen.

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Use braker bar to gently nuge bolts free. Push gently and they will go.

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Never seen or thought of the "extension through the wheel" approach, watch out for buggering up the wheel paint (pic looks like it's a bit late). I also removed the rear bumper, makes it alot easier. Do not forget to lock the cams. :cheers:

Yes new wheels are on the list of replacements

Degreased car.

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Polishing the muffler, may do Pedro's sport mod with heavy 1.5 inch stainless tubing.

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On drivers side of car suspension carriage bent 6mm, on reassembly will use PortaPower to bent into place.

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Car was damaged on the drivers side rear drive train before I got the car, I pulled and painted the lower rocker panel. New drive axle is in place so it must of been a good smack to the under carriage.

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Nice work! Keep everything very organized especially the transmission bolts. There is a lot of wrenching and even more reassembly. An organized disassembly will payoff big time. If your like me and just ripped the thing apart you might be stuck buying transmission bolts at $15 bucks a piece!

Are your wheels white by the way?

Also the header flange is busted, damn it looks like new SS headers.

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Part boxses are Golden.



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Just a quick FYI. Two of my header bolts broke off and ended up being an absolute nightmare and a common one. I bought every single bolt releaser there is and ended up towing the car to a machine shop. The headers are sweat though. I went with ebay units and they worked great. Lined up perfectly

Have had a lot of experience with undoing stuck and busted bolts. I worked my way through college as car and motorcycle restorer for a private collector, my last go-round was pulling cracked full Ti bolts for a customer. When I was done you could not tell that I had done any work on the part.

Missing bolt part (999-072-009-09), can't wait to see the hack-up work that has been done in the past.

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Pulling transmission

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Photo; Pelican Porsche.

A; 12 mm, 12 Point Triple Square Bit. available from Pelican.

D; access though top of car, my was a 16 mm head.

H; 15 mm nut, access from behind transmission.

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Need to pull intake for transmission to clear, replace with Pedro's mod on his website.

This is an interesting fact as I was also missing the same bolt on my 98'. Wonder if this is common.

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De-greased transmission.

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My manufactured by Yugo shift linkage is in very bad shape, going to see if I can have new ends made.

I'm inspired by what you and others on this board are capable of doing to your engines! Thanks for posting your progress and pictures.

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Getting stuff organized for tomorrow.

Man, after all that hard work just looking at all the hard work...I need a couple good old cold beers. Keep em' coming...gota go and get a case or two just to cover the rest of your post. :cheers:

WoW! Great work kashmir! I was going to suggest we do some of the work together but you are WAY TOO ORGANIZED! Not bad but I work like a "cave man" compared to laying out your tools - like a surgeon! Care to operate on an 02 S, doctor?

Replaced the Porsche/Yugo shift ends with DIY ones.
 

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Pulling clutch.

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Lock flywheel with big zip tie.

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Use hand impact to help loosen bolts.

Then use breaker bar to undo bolts, then remove flywheel.

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Finally to the back of engine. Nice no oil leaks.

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The ims bearing cover.