Oil Leak - Pulling Trans to change RMS, IMS, Clutch, etc

[drbodzin]

Today was a full day of working on the car. Started the day by attacking my filthy transmission and getting it cleaned up and ready to be re-installed.

The transmission was super dirty.





My wife just had to get a shot of me doing my work.



Here's the trans all nice and clean after some scrubbing and power spraying.





Here's the main shaft with the throw out bearing tube removed and ready for a new tube, seal and o-ring.

Does anybody know the torque values for these screws. I can't find them anywhere.

[drbodzin]

Then is was on to installing the clutch and pressure plate. But first I had to tighten the flywheel bolts. In order to do the the 120 degrees after torquing to 19 ft-lbs I used an angle measurement tool. I tried to locate the printed degree wheel from 101Projects.com, but it impossible to find it. So I had to improvise.

Locked the flywheel with a $0.75 metal strap from Home Depot. Worked great.



Attached the angle measuring tool (has a magnet) to the side of the breaker bar and noted the angle. Then calculated what the angle would be after 120 degrees. I think I liked using this method a lot and would recommend it to any one else.





I'm installing a new clutch disk and pressure plate for the 987 instead of the 986. Read that it was a nice upgrade.



Guess there is a side that is suppose to face the trans. Make sure you install it the correct way.



The new 987 pressure plate.



All done with the clutch install.

[drbodzin]

Last project of the day was to remove the old water pump and thermostat and install new ones. The new thermostat is a low temp unit.

Here are the olds and new units. It was pretty tough to get to all the screws to remove the units. I really thought it was going to be really hard to get some of the screws back in. Really tight quarters, especially the top left screw on the themostat.



But, I was able to get the new one back in without too much trouble. I then installed the water pump - forgot to take a picture though.

[AKnowles]

Originally Posted by drbodzin

Really tight quarters, especially the top left screw on the themostat.

Just an FYI for the next time, or the next guy, but I didn't have any problems getting to any of the bolts on my 99's thermostat or water pump. I used a 1/4" drive socket with a 1 1/2" (or so) drive extension to remove and tourque them down. using the extension or my fingers I was able to the bolt in question form the top to remove it. However, I already did have the water pump out at this point. Maybe that was the difference.

Putting it back together it was very easy to use the extension to start the bolt in the threads and tourque it down. FWIW, I repalced the water pump, thermostat, and all the hoses without removing the motor mount (as recommended) as well. I'm not sure if this is a quick of the 99s or not, but it was much easier to do the work than the messages I'd read here or on RennList.

[drbodzin]

Got back to working on my car today. I wasn't planning on replacing the air box with the cold air intake (for the super charger kit I will be installing later this year), but it seems it would be easier with the transmission out. So I did that first. Since I had no plans of ever using the stock air box again, I was able to get it out (without removing stuff) by cutting it up with a dremell and taking it out piece by piece.

[drbodzin]

Got the transmission back in today as well. Wasn't too hard to do.

New throw out bearing, guide tube with main seal and o-ring.

[Paul]

FSM says 26 ftlbs for the guide sleeve for the release bearing on transmission housing for a 97-99 Boxster 5 speed.

[drbodzin]

Originally Posted by Paul

FSM says 26 ftlbs for the guide sleeve for the release bearing on transmission housing for a 97-99 Boxster 5 speed.

Awesome! Thanks Paul

[Meir]

Very nice Doc.
You really need to elaborate on your cleaning technique.

[drbodzin]

Originally Posted by Meir

Very nice Doc.
You really need to elaborate on your cleaning technique.

Ok, to clean I just used Gunk Engine Cleaner. Then a small wire brush to loosen the really stuck on stuff. Then used a bunch of old rags to wipe most of it off. Final step was to use my pressure washer. I'm pretty sure a high pressure water hose would work just as well.

[woodsman]

your work is inspirational, your method, calming. You make it all seem so easy and worry-free! Thanks again for detailing all of this

[drbodzin]

Originally Posted by woodsman

your work is inspirational, your method, calming. You make it all seem so easy and worry-free! Thanks again for detailing all of this

Thanks for that comment. Nice to know Now everyone take a deep breath and repeat after me - "oooooohhhhhhmmmmmmmm". Just kidding. Get out there and tackle those DIY projects!