yesterday, I replaced the ignition switch on my 04 S. I removed the 90 degree elbow A/C duct and that made it easy.

....continued working on my 2000 S. It is getting all new suspension, bearings, struts and brakes. Today I replaced the front wheel bearings and put the springs back on the new front shocks...Its going together nicely....

Ugh
 

..so today I will be taking the front struts back apart. I forgot to inspect/clean/regrease the strut bearings. Clearly, things were going too well to there not to be a snafu.

Tracked it at Sebring.

I replaced my G86.00 with a 012 DVP from 1.6L FWD B5 passat for the shorter ratios.
And also hoping the gearbox was the source of my horrible drivetrain slack and not the axles.

Edit:

DVP gear ratios:

Final drive: 4.556
1st Gear = 3.5
2nd Gear = 2.118
3rd Gear = 1.3
4th Gear = 0.943
5th Gear = 0.789

Calculated top speed for each gear, keep in mind my 2.5 has 6700 rpm redline

G86.00
1st Gear = 61.85 km/h
2nd Gear = 102.21 km/h
3rd Gear = 151.49 km/h
4th Gear = 210.38 km/h
5th Gear = 274.03 km/h

DVP
1st Gear = 52.81 km/h
2nd Gear = 87.27 km/h
3rd Gear = 142.18 km/h
4th Gear = 196.01 km/h
5th Gear = 234.27 km/h

I like your numbers, but the first thing that comes to mind is: is the new gearbox designed for your torque?

That is a great question to which I have not found a perfect answer.

The case should be the same.
By comparing part numbers it looks like most bearings are the same but some are not.
First and second gears have same ratios and the part numbers are the same.
But DVP has weaker diff.

Conclusion:
DVP is not as strong as G86.00, but time will tell how well it handles the increase in torque.
The 1.6L passat has 148 nm of troque while the 2.5L M96 has 245 nm of torque.

Over the weekend I met with friends and cruised some back roads in southeastern Oklahoma.
<iframe width="560" height="315" src="https://www.youtube.com/embed/W-f5nk7G0Co?si=egdua5e6FQRkXrVq" title="YouTube video player" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen></iframe>
:cheers:

I drove the Boxster to this morning's blood drive. They were able to take my donation quickly, the nurse had an especially good aim today, -and- they gave me a free t-shirt. I took the long way home, making a point to take the curviest roads in my part of the world. It's been a good morning...
http://986forum.com/forums/uploads02/0201744644655.jpg

cheers - dj

At the weekend i went to an owners meet at my local Porsche specialist. Massive turn out and some very fancy metal. Mines the blue 986.https://uploads.tapatalk-cdn.com/202...cc35eb06fe.jpghttps://uploads.tapatalk-cdn.com/202...588d74b38a.jpghttps://uploads.tapatalk-cdn.com/202...2ce8fc7645.jpg

Sent from my SM-A546B using Tapatalk

Today i tried charging oil again, and ended up stripping the oil drain plug.. god damn it.

Now waiting for a new plug in the mail, and reading about ways to get the old plug out.

Noticed a small oil leak. After getting it up in the air, to my relief, it wasn't the RMS, but the spark plug tubes. Since I had three lying around, installed in Bank 1. After 26 years, the small o-rings were squashed flat. I'll get three more and preemptively do Bank 2.

I had the same issue, as the previous owner had really torqued it down. I bought this kit and was able to get it out with no issues.

https://www.amazon.com/dp/B07YBWNCZV?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

Thanks, but link was dead. I'm probably going doen the bolt extractor route. Tried making a slit in it with a dremel and using hammer and screwdriver to turn it but no luck.

I think they meant to post something like this:

https://www.amazon.com/Topec-Extractor-Multi-Spline-Premium-Rounded/dp/B07YBWNCZV/ref=sr_1_1_sspa?crid=1ZPGVUCA3OCPQ&dib=eyJ2IjoiMSJ 9.wqxYssN0rw7Po6QpnmO5TQ.8WaUAAkRp88wET3JwgzjbSEx0 CC91sP3jUH-KB0Ae_c&dib_tag=se&keywords=B07YBWNCZV&qid=1745009 707&sprefix=b07ybwnczv%2Caps%2C721&sr=8-1-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&th=1

EDIT:

Well ****************. That doesn't work, either.

If you go to Amazon and paste this in the search bar, you'll get a few results: B07YBWNCZV

Weird, the link works when I click it, but not when I paste it. Just search Amazon for this: Topec 25Pcs Screw Extractor Set, Hex Head Multi-Spline Easy Out Bolt Extractor Set, Premium CR-MO Steel Rounded Bolt Remover

Thanks. Found something similar in a tool shop nearby. Gonna try it when new plug arrives.

Corrected my ignition steering lock sticking when the key was removed.
I pulled the key tumbler, and removed the electronic portion on the back of the switch.
Worked the locking rod with a screwdriver and some silicone lube until the locking bolt was freely moving.
Reassembled ignition and tested like new