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Old 06-29-2006, 10:47 AM   #1
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Join Date: Apr 2006
Location: wv
Posts: 57
intermediate shaft seal and cover

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.
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