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

So, I've completely restored my 1998 Boxster. You can see the project here: http://986forum.com/forums/show-tell-gallery/43078-1998-boxster-project-complete-restoration.html

Now its time to tackle the mechanical stuff. She's got a small oil leak right where the trans and engine mate. I'm guessing its the RMS, but I suppose it could be the IMS.

So today I put her up on my lift and started the process of pulling the transmission. I got all the parts that need to be removed just prior to pulling the trans done. I will likely pull the trans on Saturday.

My plan is to replace the IMS with the LN Dual Row Bearing, RMS, and install a new 987 Clutch and Pressure plate. All the new parts are in-hand and ready to go!

Any advice from those who have done this project before is welcome :)

One question I do have is that both the Bentley Manual and the 101Projects manual both say to remove the muffler. I have an aftermarket exhaust (like a Borla) and there seems to be plenty of room between the exhaust pipes and the back end of the transmission. I would like to attempt removing the trans with out taking off the muffler. Has anyone else attempted this?

I will update this thread along the way and share any insights I gain along the way.

Here is the oil in the garage. Mind you this is froma few months of sitting there.

http://986forum.com/forums/uploads01...1368249463.jpg


http://986forum.com/forums/uploads01...1368249532.jpg

Here is a close up of where the oil is dripping from.

http://986forum.com/forums/uploads01...1368249596.jpg

Detached the CV Joints from the Transmission

http://986forum.com/forums/uploads01...1368249664.jpg

Looking up at the Back Up Switch on the Clutch Slave Cylinder

http://986forum.com/forums/uploads01...1368249776.jpg

Unplugged the Back Up Switch Harness

http://986forum.com/forums/uploads01...1368249838.jpg

About to disconnect the Shift Cables from the Transmission.

http://986forum.com/forums/uploads01...1368249910.jpg

Sorry Doc,

You will need to remove the exhaust, at least the muffler portion anyway. Besides, it allows you to be able to "sit up" inside the tranny area to get your IMS in straight and torque the bolts properly.

Make triple sure you lock down the engine at TDC VERY WELL. I used 2 cam locks AND a separate bar on the Flywheel bolts, and the pin in the Flywheel. May have been overkill but I was not going to let the patient die from a timing issue.

There ARE several instructions out there, be careful which you choose!

IMHO @Meir produced the most helpful and best writeups. @Meir's instructions were almost 100% accurate. I consulted instructions from 5 different authors, the least helpful were from LNE. I am not saying any more on the subject.

expect the dualmass flywheel to need replacement as well:(

Thanks for the heads up about locking in tdc. Ive already read a bunch of instructions and watched videos on YouTube. Where do I find the right up you're referring to?

Why should I expect this? From the oil leak? Or just as a routine thing?

The elastomer layer in the flywheel does not like oil, tends to soften it. Check it for twist per OEM specs, if it is out, it has to be replaced.

Why should I expect this? From the oil leak? Or just as a routine thing?

Hi D.
This is the link to my expiriance that Homeboy is talking about.
http://986forum.com/forums/performance-technical-chat/37984-winter-project.html
Will be happy to lend you the LN tools in case you need.
Good luck.

Huh, that explains why my flywheel wouldn't bounce back…live and learn.

Anyway, drbodzin - here is the link you asked for…

http://986forum.com/forums/performance-technical-chat/37984-winter-project.html

Good Luck!

Dept. of Redundancy Dept.

Thank you! I already have the tools though.

I'm able to twist the flywheel about 10mm in each direction by hand. Is it suppose to spring back to the same spot? It goes back, but not with a sudden spring. Sorta "eases" back.

Got more done today. Ended up taking out the muffler and both cats. Got the transmission out today. Took the pressure plate off too. Next, the flywheel, etc.

http://986forum.com/forums/uploads01...1368326651.jpg

To support the engine, I just used some wood. I will definitely say this job was made a lot easier with the scissor lift. Not sure I would have done this without it.

http://986forum.com/forums/uploads01...1368326688.jpg

And here she is with the transmission dropped out.

http://986forum.com/forums/uploads01...1368326724.jpg

Doc,

What the hell. You're a chiropractor, right? Where did you learn to wrench? How do you have the time? ...just curious. Enjoying the step by step photos; thanks.

Great time to replace the AOS, oil fill tube, and the coolant tank while they are "easier" to access.

Your FW is good.
It doesn't need to spring back to the starting point, bat has to go back ther, and twist the same way to the other side.
When doing my project, I decided to replace the FW anyway ( thought I'm going to keep my car for ever). The new FW, acted axactly the same as the old one, only required a bit more force to twist.

+1.
I also replaced the oil filler tube.
Don't even want to imagine what it takes to do that task with the trans on.

Was wondering the same thing! The scissors lift makes a big difference. Impressive job Dr:cheers:

Well that's a good question. In my youth I dropped a few VW bug engines and transmissions. Its been a long time though.

Yes I'm a chiropractor. But I don't see patients any longer. I did for nearlly 20 years. But now I serve the chiropractic profession through my software company. Which gives me a lot more flexibility in my schedule and time to spend on my hobbies and stuff.

This forum has helped a lot in knowing what and how to wrench on the Boxster. Plus I got some good manuals and there's plenty of online video tutorials. :D

Hi Paul
Thanks. What is an AOS?

Air Oil Separator.

http://ts3.mm.bing.net/th?id=H.50594...h=179&c=7&rs=1

Here's a picture of when I did mine (even easier with the motor on a lift table)

http://i33.photobucket.com/albums/d6...1/P6250471.jpg

This tool makes replacing the RMS correctly as simple as unwrapping a stick of gum.

http://i33.photobucket.com/albums/d6...1/P7070568.jpg

Oil fill tube:

http://i33.photobucket.com/albums/d6...1/P7090676.jpg

why would the oil fill tube need to be replaced? what goes wrong with it?

Age and vibration, it is attached to the motor which rocks on its mount when compared to the oil fill cap which is mounted on the firewall. Also a failing AOS causes low vacuum that collapses the tube when off throttle.

In regards to the RMS, I use the sheet metal screw method to remove them.

http://i33.photobucket.com/albums/d6...1/P6250473.jpg

Wow that was QUICK!!! thanks for your expertise and the good pictures. I was going to put my tranny back in today but may now wait to install the oil fill tube since mine is leaking alittle- the AOS was replaced about 50 miles before I stopped driving it last fall. Is it a concern about air pressure/vacuum?
PS How the heck did you take the last picture?...mechanics secret third hand?..

When a AOS fails it can introduce high vacuum levels to the crankcase and since the oil tube dumps into the crankcase, the high vacuum levels can make it collapse and ultimately leak.

would a bad AOS cause a strong oily odour around my car after shutting it off?

Have any of you replaced the transmission Main Shaft Seal? Any advice? Thinking I want to do that since I have the transmission out.

And Paul, thank you for posting the pics of your work.

On a 6 Speed… Instructions say to drill a hole and insert a drywall-type screw and then, using prybar/pliers you can extract. I found that part to be true.

The tricky part was putting the transmission seal back in! Make sure you get it in FAR ENOUGH! If you are replacing the Throwout Bearing guide Sleeve, as you should, take the old one, invert it, and insert it FORCEFULLY (up to and including banging it with a mallet HARD). It MUST SEAT very well up against the lip of the transmission housing to seal.

My PO did not seal it well and ruined the clutch/flywheel/Throwout Bearing. There was also a couple pounds of grease mixed with dirt INSIDE the tranny housing…it was a mess!

TEST IT BEFORE YOU INSTALL:
CAREFULLY tip the transmission housing forward so you can test the seal for runs, drips or errors. Also, IF you notice ANY transmission fluid leaking out at time of re-assembly… the seal is NOT SEATED ENOUGH.

Here is a pic of the seal in question.
http://986forum.com/forums/uploads01...1368536440.jpg

Again, this is a Boxster S model, with a 6 speed. The 5 speed has a larger flange and is a larger diameter.

Hope that helps you get it together!

Homeboy, thanks for that detail instruction on Main Shaft Seal. That will help me a a lot.

Today I drained the oil, removed the flywheel and cleaned up the back of the engine to get ready for the RMS and IMS replacement work. I also decided to get a new flywheel. The old one is probably ok, but what the heck.

I was surprise to see the the rear of the engine was not as messy as I had expected. I thought I would see evidence of oil leak, but not so much.

Here are the pics before I cleaned it up. If any of you have any thoughts about what you see, let me know.

http://986forum.com/forums/uploads01...1368591689.jpg

http://986forum.com/forums/uploads01...1368591731.jpg

http://986forum.com/forums/uploads01...1368591782.jpg

And here it is after some clean-up.

http://986forum.com/forums/uploads01...1368591836.jpg

http://986forum.com/forums/uploads01...1368591883.jpg

jeez, now I wish I had cleaned mine before I put the clutch and flywheel on again...a car that's loved , shows it

Looks like the leak is from the IMSB flange, so good catch. Did you check the cam deviation before you took it apart? Was there any metal in the oil filter or the sump plate?

Keep the updates coming.

Hi san rensho,

The after pictures you are referring too are "just" the cleanup of the engine case. I still have not replaced the IMS yet. But I thought the same thing about where the leak was coming from.

There wasn't any metal in the oil. I plan on removing the RMS and IMS tonight or tomorrow. I will post pics once I do.

However, there is a ton of oil in the bell housing of the transmission. So I am also thinking it could also be from the transmission Mail Seal, as it is much oilier than the engine was.

Here is the RMS install I did today.

http://986forum.com/forums/uploads01...1368855986.jpg

Here is the install tool with the new RMS on it.

http://986forum.com/forums/uploads01...1368856052.jpg

http://986forum.com/forums/uploads01...1368856105.jpg

http://986forum.com/forums/uploads01...1368856148.jpg

http://986forum.com/forums/uploads01...1368856198.jpg

Here is the IMSB Install I did today. Of course I had locked the exhaust camshaft on the passenger side with the cam lock tool with the crank at top-dead-center first.

This is the old IMSB Cover removed.

http://986forum.com/forums/uploads01...1368857359.jpg

Once I got the cover removed, I inspected the old IMS. It looked as good as new. There was no play in the shaft. It seemed to be just fine so I started to think I would just leave it. If I had not already purchased the new bearing, I would have just left it in. But since I already had the new ceramic bearing, I decided to proceed.

http://986forum.com/forums/uploads01...1368857421.jpg

http://986forum.com/forums/uploads01...1368857600.jpg

http://986forum.com/forums/uploads01...1368857639.jpg

The bearing came out easier than I thought.

http://986forum.com/forums/uploads01...1368857700.jpg

http://986forum.com/forums/uploads01...1368857750.jpg

Here is the new IMS bearing with the install tool attached. Was in the freezer for a few days.

http://986forum.com/forums/uploads01...1368857902.jpg

The new bearing went in perfect. Again, was easier to do than I thought.

http://986forum.com/forums/uploads01...1368857999.jpg

And the new cover plate installed.

http://986forum.com/forums/uploads01...1368858152.jpg

I just love watching these DIY's. You are obviously very particular and it shows!

Great work, beautiful Boxster you have there....worth every minute of your efforts.

So, do you plan to investigate the tranny seal further?

Well done! Using the correct tools always produces a better chance of success.

How much oil was in the IMS tube?