winter project

[Meir]

Hello guys.
I’m preparing for my “winter project”, and right now I’m in the stage of collecting the needed parts.
My car is 2001S with 77K.
The plan is doing the following:

1. Fuel system flush (got Techron)
2. Drain oil and coolant (got washers for both drain plugs).
3. Fix a small leak from oil pan (got Loctite 5900).
4. Replacing fuel filter. (got filter)
5. Replacing front engine mount (got the mount)
6. Removing transmission.
7. Replace O-Ring on oil cooler (got the O-rings).
8. Replacing AOS with all pipes and O-Rings including oil filler tube (got all parts of AOS system and tube).
9. Replacing coolant tank (got tank).
10. Replacing IMS bearing (will order once transmission is off the car, and I will know which one I need)
11. Replacing RMS, transmission shaft seal. (need to order)
12. Replace flywheel if needed.
13. Cutch kit (got disk, pressure plate and release bearing)
Dose the order of execution makes sense?

Also need to order:




For the clutch replacement, I was wondering if the highlighted parts are necessary/ recommended to be replaced, and is there an alternative to the highly priced grease.
Will appreciate your opinion if I’m missing any parts (Or am I about to order parts that I don’t necessarily need), or if there are other thing to do “while in there”.
Thanks in advance.
Meir.

[Kenny Boxster]

Hello Meir,

It is not a bad idea to order the highlighted items. As for the pilot bearing, it was already included in my Sachs clutch kit, so you may end up with two of the same part. My kit, however, was for the 2.7L. I changed my clutch with just the Sachs kit, new pressure plate bolts, and clutch alignment tool. My kit came with a clutch disc, pressure plate, throw out bearing, pilot bearing, and special spline lubricant.

[944boy]

And if you get a new flywheel it comes with a pilot bearing installed as well.

[Meir]

Originally Posted by Kenny Boxster

Hello Meir,

It is not a bad idea to order the highlighted items. As for the pilot bearing, it was already included in my Sachs clutch kit, so you may end up with two of the same part. My kit, however, was for the 2.7L. I changed my clutch with just the Sachs kit, new pressure plate bolts, and clutch alignment tool. My kit came with a clutch disc, pressure plate, throw out bearing, pilot bearing, and special spline lubricant.

Hi Kenny.
i have the Sachs kit in hand, and it includes everything you mentioned accept the pilot bearing. pilot bearing is 18.95$ so it stays in the list
thanks.

[Kenny Boxster]

Went down and took a picture.


This is a picture of was included, not pictured was the packet of spline lubricant.

[Meir]

that's the one i got:
2000 2004 Porsche Boxster s Roadster 986 3 2L H6 DOHC 6 SPD Sachs Clutch Kit | eBay

no pilot bearing.
but with that price i think i can live with it.
and yes, i confirmed that the pressure plate is Sachs as well.
some of ebay sellers will sale the kit as Sachs, when the disc is made in Germany, and the pressure plate is a Chinese knockoff.
thanks for the pic.
i see you also save your old parts

[Kenny Boxster]

Originally Posted by Meir

that's the one i got:
2000 2004 Porsche Boxster s Roadster 986 3 2L H6 DOHC 6 SPD Sachs Clutch Kit | eBay

no pilot bearing.
but with that price i think i can live with it.
and yes, i confirmed that the pressure plate is Sachs as well.
some of ebay sellers will sale the kit as Sachs, when the disc is made in Germany, and the pressure plate is a Chinese knockoff.
thanks for the pic.
i see you also save your old parts

Yes! Many folks think a worn out clutch disc is useless, but it actually makes a good Frisbee to throw at the neighbor's kids.

[Meir]

Originally Posted by Kenny Boxster

Yes! Many folks think a worn out clutch disc is useless, but it actually makes a good Frisbee to throw at the neighbor's kids.

thank god you didn't replace your flywheel

[Kenny Boxster]

Originally Posted by Meir

thank god you didn't replace your flywheel

You're right! The flywheel would be far too heavy for them! Right now the children can barely throw the pressure plate!

[Homeboy981]

@Mier,

One thing that comes to mind is the locking tool if you are doing IMS, to lock in the TDC position.

Past that, your list looks like mine…except you have actually bought the parts.

Keep us posted!

[Meir]

Originally Posted by Homeboy981

@Mier,

One thing that comes to mind is the locking tool if you are doing IMS, to lock in the TDC position.

Past that, your list looks like mine…except you have actually bought the parts.

Keep us posted!

Thanks Mark.
The plan is to get the LN retrofit kit with the tools.
Looks like I'm gonna have some fun this winter. :dance:

[thstone]

There are good odds that you'll need to replace your dual mass flywheel. Its a known wear item and is usually gone by 75K miles.

[Meir]

Originally Posted by thstone

There are good odds that you'll need to replace your dual mass flywheel. Its a known wear item and is usually gone by 75K miles.

I'm on the fence with the flywheel.
Not a cheap part.
but on the other end, if I'm not gonna replace It now, I will have to do it in the near future. ( probably before the new clutch will die)
might as well get it over with.
One of the things I dislike in my car, is the clutch. It doesn't slip, but its very stiff.
After completing the clutch job, im gonna do the Slave and master cylinders.
I want to have a brand new clutch system.
Advise taken, and new flywheel is ordered.

[Meir]

So as the last parts and hardware are making their way in, I also want to make sure I have all the required tools.
Reading about transmission removal, it states that supporting the engine from underneath is needed.
In the 101 book, Whyne is using a jack stand to support the engine.
Since I'm going to use a scisor lift, the car is going to be at least 3-4 feet of the ground.
One option, is to use a 4X4 cut to size from the garage floor to the Engine boss.
Other option is to secure the engine from the top using this:
1000 Lb. Capacity Engine Support Bar
Has anyone used it on a boxster?
Based on the method I will use to secure the engine, I will need to select a transmission jack, so any opinion/suggestion will be appreciated.

[Kenny Boxster]

Hi Meir,

Any engine support bar should be fine, as a lot of forum members have used them in the past. My understanding is that the Boxster engine weights around 400-500 pounds so the support bar should be more than adequate. When I took out my transmission, the car was on jack stands, so I just used a jack like Wayne. An engine support bar would be a good idea.

[Meir]

Originally Posted by Kenny Boxster

Hi Meir,

Any engine support bar should be fine, as a lot of forum members have used them in the past. My understanding is that the Boxster engine weights around 400-500 pounds so the support bar should be more than adequate. When I took out my transmission, the car was on jack stands, so I just used a jack like Wayne. An engine support bar would be a good idea.

thanks Kenny.
just wasn't sure if this thing will fit on the sides rails.
worst case i will adapt it.

working with this support will help me a lot. it will allow me to rise and lower the car during the process, to get access to some top bolts, and also use a low profile transmission jack.

[san rensho]

I've also seen pictures where guys just wedge a couple of pieces of 2X4 between the engine and the frame to support the engine. Never done it myself so can't say if it works.

[san rensho]

Oh, what about the waterpump? General consensus is to replace it every 5 years, 50k miles or so as a wear item. Once you have the motor mount out, the access to the WP is a breeze and makes it a really easy job.

[Meir]

Hi San.
Water pump was replaced last summer (2K miles ago), along with all rear water hoses, screws, guskets, and LN low temp thermostat.
Also flashed the system, and filled it with the new red coolant.
Smart thought though. Shuld have done the engine mount back then, but I was still a nooby.
As for the 2X4. It might work, but for the price of the support bar, I might just do it the right way.

Thanks.

[Ghostrider 310]

The Aluminum scissor jack the car came with is free and should make an excellent support as long as the car isn't too high off the ground to use it.