07-14-2011, 07:51 PM
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#1
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Rear Cross Member Installation
My 01 has been up on a lift for months, over the weekend I installed a used motor with lots of new parts. I'm at the point of trying to bolt up the black rear cross member that runs side to side underneath the the bell housing.
The bolt holes will not line up side to side, they are off by about 1/8".
What is the best way to pull in the attachment points?
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-14-2011, 09:11 PM
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#2
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Registered User
Join Date: Jul 2010
Location: California
Posts: 1,859
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Paul,
The cross member is short of lining-up with the holes?
__________________
Jäger
300K Mile Club
Last edited by Jager; 07-14-2011 at 09:13 PM.
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07-15-2011, 08:43 AM
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#3
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Registered User
Join Date: Nov 2006
Location: Bastrop, TX
Posts: 705
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its because it on the lift and the body has flexed.
easy way...... go buy a strong rachet strap tie down.... strap it and rachet it together.
__________________
2002 S
Pedro rear stabilizer bar, CF strut braces, Maxspeed headers with 100 cell cats, Fabspeed cat bypass pipes, H&R springs with M030 setup, TRG rear links, EVO air intake, B&M Short shift kit, Raby IMS upgrade, Raby underdrive pulley
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07-15-2011, 11:26 AM
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#4
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Registered User
Join Date: Oct 2008
Location: O.C. CA
Posts: 3,709
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Quote:
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Originally Posted by Paul
My 01 has been up on a lift for months, over the weekend I installed a used motor with lots of new parts. I'm at the point of trying to bolt up the black rear cross member that runs side to side underneath the the bell housing.
The bolt holes will not line up side to side, they are off by about 1/8".
What is the best way to pull in the attachment points?
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If you just loosen the 2 rear suspension strut to frame bolts per side you can move them to lineup the bolt holes & then push them outward as much as possible to maximize rear track width & negative camber. No matter what you do you will need to check the rear alignment settings afterward.
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07-15-2011, 08:04 PM
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#5
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Quote:
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Originally Posted by jhandy
its because it on the lift and the body has flexed.
easy way...... go buy a strong rachet strap tie down.... strap it and rachet it together.
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Have you done this?
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-15-2011, 08:09 PM
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#6
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Quote:
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Originally Posted by BYprodriver
If you just loosen the 2 rear suspension strut to frame bolts per side you can move them to lineup the bolt holes & then push them outward as much as possible to maximize rear track width & negative camber. No matter what you do you will need to check the rear alignment settings afterward.
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Thanks, I was trying to avoid a $200 alignment, but as I looked at it last night, I kinda figured that your solution was probably the best choice.
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-16-2011, 09:00 AM
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#7
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Registered User
Join Date: Nov 2006
Location: Bastrop, TX
Posts: 705
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You are only pulling in 1/8 inch. By using the strap you are reproducing the pull of the crossmember.
If you undo the tower, you need to pay $$ for an alingment.
__________________
2002 S
Pedro rear stabilizer bar, CF strut braces, Maxspeed headers with 100 cell cats, Fabspeed cat bypass pipes, H&R springs with M030 setup, TRG rear links, EVO air intake, B&M Short shift kit, Raby IMS upgrade, Raby underdrive pulley
Last edited by jhandy; 07-16-2011 at 09:07 AM.
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07-16-2011, 07:58 PM
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#8
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Great solution it worked great, didn't even have ratchet it very tight.
These 4 bolts took a lot more time.
Got the car done today and took it for a ride! Great to have it back.
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-16-2011, 08:39 PM
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#9
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Registered User
Join Date: Jul 2010
Location: California
Posts: 1,859
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Paul,
I'm glad to see you're on the road again! How's the replacement motor running for you?
__________________
Jäger
300K Mile Club
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07-16-2011, 08:57 PM
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#10
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Put in a 13 hour day today, enjoyed all but the hours it took to remove those pressed in exhaust flange bolts.
No leaks, all levels seem to be holding steady. Only drove the car for about 10 miles so far, but I enjoyed every minute of it.
Great to have it off the lift, now I just have to clean up the garage!
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-16-2011, 09:02 PM
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#11
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Registered User
Join Date: Jul 2010
Location: California
Posts: 1,859
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This is great news... Now you have to change your signature block... You have compression now!
How did you get the exhaust flange bolts out, drill?
__________________
Jäger
300K Mile Club
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07-16-2011, 09:12 PM
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#12
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Changed the signature, good idea, thanks!
I used a air powered cutoff tool to remove the heads of the bolts and the rest of the threads on the other side. Tried a air hammer to knock them out to no avail.
So I drilled them out. They are made of very hard metal that destroyed a couple very good drill bits.
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-16-2011, 09:23 PM
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#13
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Registered User
Join Date: Jul 2010
Location: California
Posts: 1,859
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I know you upgraded the IMS bearing but what other, if any, parts did you ugrade on the motor? Did you install a new water pump?
__________________
Jäger
300K Mile Club
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07-16-2011, 09:34 PM
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#14
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Lots of stuff,
water pump (old one was fine)
RMS
LN IMS bearing (old one was fine, but the IMS tube was full of oil)
Flywheel (old one was shot)
pilot bearing
clutch set
AOS
Belt
Oil fill tube
Coolant tank and cap
Porsche antifreeze ($28 a gallon, ouch)
Lots of new bolts and nuts and gaskets.
engine mount (old one still intact after 89000 miles)
Royal purple tranny fluid (dealer wanted $39 a quart for Porsche gear lube!)
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
Last edited by Paul; 07-18-2011 at 07:19 PM.
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07-16-2011, 09:51 PM
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#15
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Registered User
Join Date: Jul 2010
Location: California
Posts: 1,859
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Have you used Royal Purple befiore? I am using it now and have found that it is a little stiff when it's cold but after it warms-up it is very smooth. In colder climate you might find it too stiff??
__________________
Jäger
300K Mile Club
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07-17-2011, 05:58 PM
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#16
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Drove a little over 100 miles on twisty back roads today, had to top off the coolant. No drips.
Tranny is shifting fine so far, but it's 95 degrees today.
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-25-2011, 02:45 PM
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#17
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Just got back from a 1,200 mile round trip to the Pittsburgh Vintage Grand Prix. Car survived monsoon rains on Friday in Ohio and 95 degrees temps all weekend.
Oil and coolant levels unchanged averaged about 28 MPG. 
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
Last edited by Paul; 07-25-2011 at 02:49 PM.
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07-25-2011, 03:06 PM
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#18
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Porscheectomy
Join Date: Mar 2006
Location: Seattle Area
Posts: 3,011
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Quote:
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Originally Posted by Paul
Lots of stuff,
water pump (old one was fine)
RMS
LN IMS bearing (old one was fine, but the IMS tube was full of oil)
Flywheel (old one was shot)
pilot bearing
clutch set
AOS
Belt
Oil fill tube
Coolant tank and cap
Porsche antifreeze ($28 a gallon, ouch)
Lots of new bolts and nuts and gaskets.
engine mount (old one still intact after 89000 miles)
Royal purple tranny fluid (dealer wanted $39 a quart for Porsche gear lube!)
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Did you see any scraping on the water pump blades?
http://986forum.com/forums/showthread.php?t=29542
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07-25-2011, 03:28 PM
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#19
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Porsche "Purist"
Join Date: Aug 2003
Location: Wisconsin
Posts: 2,123
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Nope.
__________________
1998 Boxster with 7.8 DME, 2005 3.6 liter/325 hp, Variocam Plus, 996 Instrument panel
2001 Boxster original owner. I installed used motor at 89k.
1987 924S. 2002 996TT. PST-2
Owned and repaired Porsches since 1974. Porsche: It's not driving, it's therapy.
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07-25-2011, 09:18 PM
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#20
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Autobahn Glanz
Join Date: Dec 2010
Location: Charlotte, NC
Posts: 1,282
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Paul, I enjoyed this thread. Us upstarts find these threads very informative and help with our confidence to take on projects. A 3.6 wow...she must pull hard!
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