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Old 04-06-2011, 02:10 PM   #17
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Join Date: Mar 2011
Location: DeLand, FL
Posts: 48
The rest of the assembly was basically the reverse of the disassembly.

Some observations:

The removal of the early muffler is a pain with that contraption of a factory bracket.

Hands-down, the hardest part of the reassembly was the single bolt that held the clutch slave cylinder. I had the car on an overhead lift and cussed for 45 minutes trying to overcome the preload on that thing in order to put a single bolt in place.

The five 16mm (16mm head) bell housing bolts were FRIGGEN' TIGHT. I had to use a 3' breaker bar on two of them to get them out. How did I get a breaker bar on those bolts? 2.5' of combined 1/2" and 3/8" entensions and a 3/8" universal joint set up so I could stand where the muffler resides and use the breaker bar from there.


Special tools:

I didn't have to buy anything, but I did modify tools I had.

1/4" drive 13mm socket got cut down to become a shallow socket to get at the bolts on the muffler bracket.

The triple-square bolt on the bell housing required that I cut down the appropriate TS bit and use an 11mm box-in wrench on it to remove the bolt.

The chain tensioner on the top of the engine required me to cut a 32mm box-in wrench so I could swing it in the confines of the engine bay.

You saw my 901:986 clutch centering tool mod. I just need to source the correct tool.

I made a flywheel retainer that was pictured earlier.



There you go. It's done. The customer (my wife) is happy to have the car back and doesn't understand all the fuss. It was running fine.........
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