[Dragonwind]

I just want to share my adventure into my big project.

Day 1
On Saturday I started the big task of removing the transmission. I bought a new DMF, clutch package and replacement parts for the transmission side. I already had the FW and Clutch package so when I ordered all the remaining parts from Pellican according to their kit I realized I ended up with some extra bits. Namely the tube guide comes with all the seals installed and the new DMF had the bearing in already. Why the kit has you buy the extra seals seems odd.

Having had the exhaust off many times that part was a piece of cake. Once the lower panel and transmission mounts came off then it was time to address the inner CV bolts. Those are a PITA. I ended up cutting a length of an allen key to get at these things....of course DUH I didn't think about rotation the wheel until today to gain better access to some.

Once those were off the transmission to engine bolts weren't too bad other than that weird 10mm triple square. What is the point of that oddball bolt? No room for any ratchet there so I gut down the tool and used a wrench. Once that was off I couldn't move the trans then another DUH...missed the one nut on the right side. Got that off and out came the transmission.

The clutch disk itself wasn't terribly old and visually looking like it had a lot of life left in it. However seeing as I was going through all this work it would be silly not to replace it. This is where I called it quits for the night.

Day 2
Pulled the DMF off. It was shot as I could rotate it beyond spec with little effort. Hopefully this solves the 3000rpm vibration as the front motor mount is newer and I inspected it last summer (still was 100%).

At this point my attention turned to the AOS. Although there was nothing wrong with the current one with 103K on the OD I decided to change it out and figured with the transmission out of the way it would be easier to address. As the 101projects mentioned the spring clamp is the biggest PITA. With the new AOS nearly installed I finally gave up on the clap and installed a more traditional adjustable hose clamp This way if I ever need to take it off again I don't have to deal with it.

The new DMF had a piece of tape on it with a message (clearly someone had bought it once before)..."this is a 5 speed flywheel. Don't let your parts man lie to you!". Hmm sounds like someone was doing a Boxster S and they sold him this. I bet once he/she got the old one off and they didn't look the same is when the note was left.

Anyways...Lifting the new DMF onto the crank is a challenge when your arms are getting tired! Once that was on came the fun of torquing down the flywheel bolts. Thank goodness for the degree wheel that you can print out from 101projects. With that done I bolted in the new clutch kit. I expected the alignment tool to be metal but it was plastic...whatever works. I already had the LN bearing and a new RMS installed on this car and they were both looking great...although not much to see on the bearing other than the cover.

I changed out the guide tube with it's seals and other bits and then spent one hour just trying to get the stupid trans back on the car. Although I was using the 101projects method of a regular jack to install I really will get a basic transmission jack becuase what a PITA that was. Finally it went in far enough that I could use the mounting bolts to help finish it along. Once that was in and the Slave Cylinder installed a quick clutch test showed it to be very smooth.

I've gotten as far as torquing the inner CV bolts but still need to re-assemble everything else. Hopefully the 17mm Hex socket I ordered will arrive today so I can change the gear oil too.

So far I have about 14 hours into it. The first time doing something I've never done before is always the longest.

I've babbled long enough.

Peace!

Chris