Go Back   986 Forum - for Porsche Boxster & Cayman Owners > Porsche Boxster & Cayman Forums > Performance and Technical chat

Reply
 
LinkBack Thread Tools Display Modes
Old 11-09-2012, 07:36 AM   #1
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
winter project

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.

Last edited by Meir; 11-09-2012 at 07:41 AM.
Meir is offline   Reply With Quote
Old 11-09-2012, 11:18 AM   #2
Moderator
 
Join Date: Feb 2012
Location: DFW
Posts: 782
Garage
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.

Last edited by Kenny Boxster; 11-09-2012 at 11:20 AM.
Kenny Boxster is offline   Reply With Quote
Old 11-09-2012, 11:30 AM   #3
Registered User
 
Join Date: Jun 2008
Location: Santa Clara, CA
Posts: 247
And if you get a new flywheel it comes with a pilot bearing installed as well.
__________________
2005 987 - 112K miles PASM + 6-speed - Daily Driver
1988 944 - 240K miles- Race Car
1974 911 Targa - new project
2009 Triumph Street Triple R - 27K mi - Blazen Orange
1976 Ford F250 camper special - tow vehicle
944boy is offline   Reply With Quote
Old 11-09-2012, 11:33 AM   #4
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
Quote:
Originally Posted by Kenny Boxster View Post
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.
Meir is offline   Reply With Quote
Old 11-09-2012, 11:36 AM   #5
Moderator
 
Join Date: Feb 2012
Location: DFW
Posts: 782
Garage
Went down and took a picture.


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

Last edited by Kenny Boxster; 11-09-2012 at 11:46 AM.
Kenny Boxster is offline   Reply With Quote
Old 11-09-2012, 11:51 AM   #6
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
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
Meir is offline   Reply With Quote
Old 11-09-2012, 11:59 AM   #7
Moderator
 
Join Date: Feb 2012
Location: DFW
Posts: 782
Garage
Quote:
Originally Posted by Meir View Post
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.
Kenny Boxster is offline   Reply With Quote
Old 11-09-2012, 12:15 PM   #8
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
Quote:
Originally Posted by Kenny Boxster View Post
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
Meir is offline   Reply With Quote
Old 11-09-2012, 12:38 PM   #9
Moderator
 
Join Date: Feb 2012
Location: DFW
Posts: 782
Garage
Quote:
Originally Posted by Meir View Post
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!

Last edited by Kenny Boxster; 11-09-2012 at 12:40 PM.
Kenny Boxster is offline   Reply With Quote
Old 11-09-2012, 06:45 PM   #10
Homeboy981
 
Homeboy981's Avatar
 
Join Date: Jan 2012
Location: Sherman, TX
Posts: 663
Garage
@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!
__________________
2002 Porsche Boxtser S - Silver & Chrome - Died from IMS failure AFTER IMS was replaced!
Homeboy981 is offline   Reply With Quote
Old 11-09-2012, 07:34 PM   #11
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
Quote:
Originally Posted by Homeboy981 View Post
@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.
Meir is offline   Reply With Quote
Old 11-10-2012, 08:48 AM   #12
Certified Boxster Addict
 
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,428
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.
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
thstone is offline   Reply With Quote
Old 11-10-2012, 06:13 PM   #13
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
Quote:
Originally Posted by thstone View Post
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 is offline   Reply With Quote
Old 11-19-2012, 05:37 PM   #14
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
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.
Meir is offline   Reply With Quote
Old 11-20-2012, 12:11 PM   #15
Moderator
 
Join Date: Feb 2012
Location: DFW
Posts: 782
Garage
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.
Kenny Boxster is offline   Reply With Quote
Old 11-20-2012, 12:20 PM   #16
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
Quote:
Originally Posted by Kenny Boxster View Post
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.
Meir is offline   Reply With Quote
Old 11-20-2012, 02:21 PM   #17
Registered User
 
Join Date: May 2011
Location: Miami florida
Posts: 1,591
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.
__________________
Current car

2000 Boxster 2.7l red/black

Previous cars

1973 Opel Manta
1969(?) Fiat 850 Convertible
1979 Lancia Beta Coupe
1981 Alfa Romeo GTV 6
1985 Alfa Romeo Graduate
1985 Porsche 944
1989 Porsche 944
1981 Triumph TR7
1989 (?) Alfa Romeo Milano
1993 Saab 9000
san rensho is offline   Reply With Quote
Old 11-20-2012, 02:29 PM   #18
Registered User
 
Join Date: May 2011
Location: Miami florida
Posts: 1,591
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.
__________________
Current car

2000 Boxster 2.7l red/black

Previous cars

1973 Opel Manta
1969(?) Fiat 850 Convertible
1979 Lancia Beta Coupe
1981 Alfa Romeo GTV 6
1985 Alfa Romeo Graduate
1985 Porsche 944
1989 Porsche 944
1981 Triumph TR7
1989 (?) Alfa Romeo Milano
1993 Saab 9000
san rensho is offline   Reply With Quote
Old 11-20-2012, 05:06 PM   #19
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,575
Garage
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.

Last edited by Meir; 11-20-2012 at 07:26 PM.
Meir is offline   Reply With Quote
Old 11-21-2012, 09:09 AM   #20
Ex Esso kid
 
Join Date: Dec 2005
Location: NY
Posts: 1,605
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.
Ghostrider 310 is offline   Reply With Quote
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -8. The time now is 11:11 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
Copyright 2018 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page