intermediate shaft seal and cover

[rodsnhawgs]

OK guys, I'm deep into the RMS removal and replacement (R&R). The seal has been fairly straightforward w/ no issues - you can see it installed in the pic. After I get this finished, I'll post a more complete story and pic history. However, for now I have a more pressing issue/problem.

The Bentley svc manual only recommends R&R of the 3 bolts on the intermediate shaft cover. But my internet research clearly shows that the recommended preventative measure is to replace the original cover a newer version which has an updated seal design. Upon this recommendation, I pulled the cover. Here's where the problem began - w/ the cover removed, the shaft had nothing to keep it centered in the opening. I am completely surprised, given all the wonderful engineering of the Boxster, that Porsche has done such a poor job of supporting the tail-end of both the crankshaft and the intermediate shaft and thus creating these leak issues. Oh well.... Anyway, the shaft shifted off-center in the opening, apparently under the chain tensioner's loads (see attached pic). Without the shaft being centered in the opening, there is no way to re-install the cover. I've loosened the chain tensioners, which offer no help. The Bentley svc manual doesn't address this issue and I can't find any info on the internet. Can any of you offer experience/insite? Thx.

[98Boxster98]

I'm WAY out of my league here, but my understanding is that there is some sort of centering tool. I remember seeing a picture of one but I don't recall where. I''ll post if I find it. I'm sure the big guns will be here soon to help you out.

http://www.renntech.org/forums/index.php?showtopic=5306&hl

[98Boxster98]

Maybe this will help:

http://www.c-speedracing.com/howto/996rms/rms1.php

[rodsnhawgs]

Thanks 98boxster98. Actually the c-speedracing link is a great documentation of the rms job. However, it doesn't address the problem I encountered. As it turns out, it was a very simple fix once the idea was planted and I felt comfortable "stretching" the chain(s). Another respondee on renntech put me on the idea. There's a good thread there on rms R&R including the intermediate shaft cover/seal issue. The thread ends w/ my question and a response which ended up solving my problem. Actually, a 1/2" drive 9/16 socket fits well in the bearing. By doing so, I was able to exert pressure to center the shaft. Gave enough confidence and experience on the force required I was able to use the new cover, nut, and a large pair of channel locks to pull everything in place. Once centered, I used the retaining nut on the bearing shaft stud to press/pull the cover into the opening perfectly. 3 new bolts and I was good to proceed w/ the rest of the reinstall. Here's the link:
http://www.renntech.org/forums/index.php?showtopic=15&hl=rms&st=20

[98Boxster98]

Hi Rod. I saw that Loren at Renntech provided an answer earlier today and I knew you were in good hands. Gotta admire a man who tackles his own RMS fix.

[MNBoxster]

Hi,

I hope you inset the RMS the proper distance. OEM is inset 11mm, but Porsche states to inset replacement seal 13mm to have the lip ride on a virgin, unblemished section of the Crankshaft. Failure to follow this could lead to early failure on the replacement. Don't remember if this is mentioned in the Bentley. Hope this helps...

Happy Motoring!... Jim'99

[rodsnhawgs]

Yes, I set it @ 13 mm. Although there was no "feel" of a groove, there was a definite visible mark. Thanks for the reminder though MN. BTW, I used the new "Cayenne" style RMS.

[rodsnhawgs]

I'll post pics of the RMS r&r (removal and replacement) sometime next week. Until then, I just wanted to give you a quick heads up on the cost. Total cost, including changing the oil (synthetic and OE filter): <$150.00 US

Parts:
gen4 Cayenne style RMS
intermediate shaft cover
4 block bolts
3 intermediate shaft bolts
8 flexplate bolts
8 qts Mobil1
1 Porsche OE filter

My labor was free

Back on the road leak-free