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Old 02-14-2017, 08:53 AM   #21
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Did not get much track time other than doing some coaching with friends. Car had a grinding noise from the rear on right hand turns under acceleration. I had removed, inspected and repacked the CV's prior to the event, so probably not the cause. Four wheel bearings will be here tomorrow.

Sway bars, GT3 LCA's, engine and trans mounts, and much more are on the way.

Still lots of work to do. Pushed the cage install back so that I will have time to get to the wiring before it goes in.

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Old 02-14-2017, 09:48 AM   #22
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Cool! Keep us informed. Pictures!
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Old 02-18-2017, 01:27 PM   #23
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Busy day in the garage, put my friends 987 on the lift first to check out a clunking noise, turns out to be a broken rear shock. He's ordering new and we will install next week.

I was planning on changing out all 4 wheel bearings today, but decided to hold off until my LCA's show up next week. Instead Larry hung around and we started pulling parts as well as installing Wevo trans mounts.













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Last edited by Lemming; 02-22-2017 at 07:32 AM.
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Old 02-20-2017, 03:06 PM   #24
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Installed the crank underdrive pulley, easy job! Still have to remove ac compressor and lines from the engine bay.

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Old 02-21-2017, 01:54 PM   #25
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The dash is out! Special thanks to forum member Meir for his excellent writeup on dash removal http://986forum.com/forums/diy-project-guides/37245-dashboard-cover-removal.html

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Old 03-12-2017, 06:46 PM   #26
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Slow progress due to work travel, was back at it this weekend. Removed secondary air pump and associated plumbing. A real pain with the engine in the car. AC compressor removed as well and low temp termostat installed. Started working on replacing the oil cooler with an S unit when I realized I was looking at an early 97 cooler installed (what the ..., I bought a '99). After searching the engine number, turns out the my engine is an early '97. Guessing a PO killed the engine (IMS) and replaced it with an 97. I should be happy it was replaced with a spec legal engine, but now I need to buy the adapter plate for the cooler.









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Old 04-10-2017, 09:25 AM   #27
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Wiring clean up and moving of the fuse box and relays to passenger compartment should be completed this week.

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Old 04-19-2017, 04:12 PM   #28
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Ok, wiring is down to where I want to go, got the essentials connected and the car turned over. I must admit, I was scared. I had the engine apart, so when I was cutting wires, I could not check to see if I had screwed up. Fuse box, relays, and alarm box are now on the passenger side. I need to clean up the wiring, seal cut ends, add mount relays for the lights and fans, and switches. That will be one good days work.

While I am waiting for electrical parts, pulled the front suspension to install the GT3 LCA'S, GT3 sway bars, and new wheel bearings (why not). Will start on the rear this weekend after spending two days at Barber watching Indy.
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Old 04-23-2017, 02:03 PM   #29
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All wheel bearings have been replaced. Had to pull the rear LCA's off as I noticed that they had torn boots. Will eventually put in some GT3 in the rear (already in front), but don't want to spend the money now, so will install stock 986 till next year.

Radiators are out and being cleaned, will remove one fan for weight. Center radiator install has begun. Pics soon.
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Old 04-23-2017, 02:44 PM   #30
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Damn that is a lot of wiring! That would be very intimidating for me and I'm sure I'd tangle a bunch of stuff up. Looks like you're getting pretty far along.
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Old 04-23-2017, 05:21 PM   #31
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All wheel bearings have been replaced.
How big of a pain is this for a DIY? I want to do mine as PM, and am debating struggling with it myself or just paying up for a shop to handle it.
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Old 04-23-2017, 11:28 PM   #32
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How big of a pain is this for a DIY? I want to do mine as PM, and am debating struggling with it myself or just paying up for a shop to handle it.
It really depends on your comfort level for the necessary suspension r&r and the bearing/hub r&r.

First question is whether you are comfortable removing & reinstalling the wheel carrier. If you can do this, you can take the carrier to a shop and have them pull the hub and old bearing, and press in the new bearing and hub, which is very straightforward.

Second question is whether you have a shop press or better yet the SIR P90 toolkit. Then you can do the hub and bearing yourself.

(*Note: It may be possible to use the SIR tool with the wheel carrier on the car, but I'm not sure what the limitations are. Front only? Rear only? What does need to be removed?)

I needed to have my shocks rebuilt over the winter, so I had my SPB buddies come over one day and we disassembled everything. I learned a lot, including how to get the wheel carrier off, and how to do the hub and bearing (we did one that day). Then, later, I did the other 5 bearings. (I bought 2 used carriers as pre-built spares, to make it easier to deal with a bad bearing at the track.) The first one I did myself went very slowly and carefully, and the rest were easier and faster with the knowledge. (I borrowed the SIR tool from one of the guys.) After doing all the bearings and hubs, with 6 wheel carriers sitting there, I started putting it all back together. No problems there other than one damaged LCA thread. It can be a bit frustrating at times getting everything to cooperate in terms of getting the carriers and fasteners out and then back in, but you just have to persist and not be on a short deadline.

I also ended up buying a few things that were either necessary or that made life easier this time and especially the next.
- 1-1/16" wrench (for SIR tool nut)
- 32mm impact socket (for axle nut)
- Makita high torque impact wrench (for axle nut and pulling hub and bearing) This is one of those things that seems like a splurge but you will wish you had a high torque gun years ago... (and capability of battery & power vs. price is much better than what you find in reviews from 3 yrs ago)
- installed a hefty bench vise to hold the carrier when using the SIR tool (not mandatory but very helpful)
- MAP gas torch to heat up carrier to make extraction and insert easier. (Also, you should put the new bearing in the freezer for a while before pressing in, for the same reason.)

Here's the SIR B90 toolkit: ("master kit" / "complete" is the one to get)
SIR Tools B90

Then the question is alignment. I *think* that if you are careful not to change anything, r&r of the wheel carrier should not move anything alignment-related. (toe link adjusters for toe, LCA shims for camber). Mine needed an alignment anyway since I also replaced a bent inner steering tie rod, so we did that after everything was put back together.

6 carriers in various states of work:


Carrier in bench vise, ready for hub extraction:

Last edited by trygve; 04-23-2017 at 11:30 PM. Reason: add quote
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Old 04-24-2017, 04:19 AM   #33
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How big of a pain is this for a DIY? I want to do mine as PM, and am debating struggling with it myself or just paying up for a shop to handle it.
As Trygve wrote, if you have the right tools and a bit of skill, it can be done. Just takes time. I always borrow my friends Matco bearing puller set (similar to B90 tool), plus I have a 12 ton press (Harbor Freight, $120). Keep the bearings in the freezer and heat the hubs to make the job a bit easier. Both front and rear bearings could be pulled and pressed in the car after dropping the wheel carrier from the shocks. If a was not replacing the LCA's, I would have done it on the car.

I had one bad bearing when I bought the car, it had to be replaced - so while I was in there!!!!

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Last edited by Lemming; 04-24-2017 at 04:53 AM.
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Old 04-24-2017, 04:26 AM   #34
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My fiberglass hard top came in last week and it's a piece of art. Very well made, excellent fit, light, and an excellent price. Purchased from Marshall Talbot at https://www.advancomposites.net/ (no affiliation, just a happy customer).




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Old 05-07-2017, 04:29 AM   #35
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Great progress on the car yesterday thanks to help from a friend. Got the center radiator installed and plumbed, reinstalled the side radiators. Will cut the heater hoses today and install a 90o bend and clamp. I plan on adding water and running it today.

Also cut the rear bumper and started fabricating the screening.

Car starts like a champ, but not seeing tach, oil, fuel, etc on the cluster. Cluster does light up and show miles and such. Guessing I have a missing ground, will try to run that down today as well.
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Old 05-08-2017, 05:46 AM   #36
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Got all of the instruments gauges working yesterday, missed one stinking wire! Add distilled h2o and water wetter, system seems to be working well.



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Old 05-11-2017, 07:05 PM   #37
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Worked on the exhaust today, in place and ready for final welding.







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Old 05-12-2017, 04:58 AM   #38
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I did the wheel bearings myself using a borrowed SIR tool set. The only part I wasn't able to do myself was remove the inner bearing center from the hub after I pulled it, but only on the backs (2000 S), so I dropped them at my mechanic and he cut them off for me. I don't have any grinding/cutting tools or a good vise to hold stuff.

Shameless plug - if you haven't gotten your 2 new rear LCA I have 2 extra new in box items for sale Save a few bucks Price drop to $125
http://986forum.com/forums/boxster-parts-sale-wanted/66069-2-meyle-lca-coffin-arms-sale.html
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Old 05-13-2017, 06:25 AM   #39
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Shameless plug - if you haven't gotten your 2 new rear LCA I have 2 extra new in box items for sale Save a few bucks Price drop to $125
http://986forum.com/forums/boxster-parts-sale-wanted/66069-2-meyle-lca-coffin-arms-sale.html
Already purchased and installed.
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Old 05-13-2017, 07:32 AM   #40
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Already purchased and installed.
I should have checked the date build looks great!

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