What could possibly go wrong? - 986 Forum - The Community for Porsche Boxster & Cayman Owners

truegearhead · 06-07-2012, 06:43 AM

Having just done the job myself I can tell you a lot can go wrong! My car for example has been down for 2 weeks and is at the machine shop right now. If time is on your side its not bad. There is a lot of wrenching involved! And you will break header bolts which has been my nightmare. Couple of pointers

1. Make sure you have all the tools! You'll need some odd ball torx bits, a 32mm socket etc.
2. Keep track of what bolts went where, especially the transmission bolts
3. You need to pay a lot of attention to the IMS bearing removal process! Make sure your rested for this
4. This worked for me but I'm not sure if it was a mistake. When I removed my ims bearing cover the bearing shifted and no longer lined up with the hole in the block. To get around it I grinded down an angle on the inside of the tool to guide it in. Once I pulled it part way into the tool I adjusted the alignment bolts to keep it straight.
5. I removed my entire exhaust as one piece headers to exhaust tip and then soaked all the bolts in PB blaster and reinstalled he exhaust as separate pieces.
6. Its a great time to rebuild your drive axles. With everything removed its easy to replace the boots.

black_box · 06-07-2012, 07:15 AM

Do the headers actually have to be removed for the job? Or can I get away with just taking off the mid-pipes? I only had to do the midpipes for my axle removal.

Time is sort-of on my side. The problem will be if my car gets stuck on the lift for an extended time, as it's not my lift. I want to be able to knock out the job in one weekend.

harryrcb · 06-07-2012, 08:21 AM

Quote:

Originally Posted by black_box

Do the headers actually have to be removed for the job? Or can I get away with just taking off the mid-pipes? I only had to do the midpipes for my axle removal.

Time is sort-of on my side. The problem will be if my car gets stuck on the lift for an extended time, as it's not my lift. I want to be able to knock out the job in one weekend.

No need to take the headers off unless you are replacing them. BTW don't remover the slave cylinder and then try the clutch you will have brake fluid all over the place. there is no clutch fluid it uses the brake master cylinder tank for it's source. A stiff clutch usually means that its time to replace.