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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Tue Feb 06, 2018 8:22 pm    Post subject: Reply with quote

Picked this haul up from OPC:



Fitted new o ring seals and alloy washers to my tensioners ready to go back.



I like putting new parts back on the car.
 
  
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deMort
Zolder


Joined: 21 Mar 2015
Posts: 5172
Location: Brighton


PostPosted: Tue Feb 06, 2018 8:29 pm    Post subject: Reply with quote

This is like being at work Thumb

Guide tube is old though .. at least the packing is .. not uncommon .. i fitted a targa roof cable the other day .. new with a 2012 date stamp .

Btw .. what launguage is that ? the tensioner names ?
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7pm - 9pm
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Tue Feb 06, 2018 8:34 pm    Post subject: Reply with quote

Demort wrote:
This is like being at work Thumb

Guide tube is old though .. at least the packing is .. not uncommon .. i fitted a targa roof cable the other day .. new with a 2012 date stamp .

Btw .. what launguage is that ? the tensioner names ?


Weird, huh considering you should change it with a clutch you would think they would be faster moving.

That is English... "Vertical" and "Horiz" for horizontal.... its the orientation of the holes they came out of.... so i don't get confused!
 
  
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deMort
Zolder


Joined: 21 Mar 2015
Posts: 5172
Location: Brighton


PostPosted: Tue Feb 06, 2018 8:37 pm    Post subject: Reply with quote

Aghhh .. my question is answered bless you Very Happy
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Fri Feb 09, 2018 3:42 pm    Post subject: Reply with quote

£54 later and the caliper has been mounted on the mill. Apparently this nipple had a bit of a tool and a snapped drill bit stuck in it some time ago.



I also had them remove the rounded (oops my fault) pipe fitting. Thanks https://www.lancasterengines.co.uk
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Sun Feb 11, 2018 8:53 pm    Post subject: Reply with quote

Time for the next thrilling instalment!

GEARBOX IS FINALLY BACK ON!

IN THE SNOW!!!!

First I replaced the tensioners, removed the camlock too and checked the cam hadn't moved. Put a new cam cover plug in. Removed flywheel lock drill bit.

Old RMS out with drill and screw method. You can peer in at the primary chain tensioner pad with the RMS out. This looked fine really, it must be worn but the chain wasn't disappearing into it.

New RMS awaiting install with Gixxer's install tool at the ready:



Slide it on (I had to cut out the install tube to clear the roll pin)



Drive home with the tool lent by Gixxer to exactly 13mm deep:


LUKy me, new flywheel.



New bolts too, tightened to just 25nm and then marked and turned 120 degrees further. Can just see my flywheel lock made of scrap:


Cleaned flywheel and cover plate with brake cleaner. love this stuff.

Cover plate with new e10 bolts:


Old release bearing guide tube, worn slight grooves! This was replaced with new, the bolts put up a fight! I lightly greased it.


More brake cleaner actions and new clutch release hardware fitted up:


No more pics as it was FREEZING. Got the gearbox into position, jacked up a bit, fitted up the new clutch slave (with plastic end) and hose. crack the bleed nipple open as otherwise you fight the system. man. Grease from clutch kit on splines and mainshaft splines.

Jack up the gearbox and simply slide home.

Yeah right, I wrestled with that thing on my back for 2 hours, up a bit down a bit. engine up, engine down wiggle around.

Eventually it goes on and you can pull it home with the super long bolts.

Special tools: RMS installer, e10 socket for clutch cover.

I think I have frostbite in my feet. The rear mount can wait.
 
  
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Marky911
Kyalami


Joined: 04 Jun 2009
Posts: 1788



PostPosted: Sun Feb 11, 2018 10:57 pm    Post subject: Reply with quote

"In the snow"

You're crazy, but I like it. Grin

I was whinging about the cold, just standing chatting while collecting mine yesterday. You wouldn't catch me crawling underneath it.

You're on the home straight now though. Great job! Thumb
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Tue Feb 13, 2018 10:28 pm    Post subject: Reply with quote

Marky911 wrote:
You're on the home straight now though. Great job! Thumb


Thanks for the encouragement, it really does mean a lot when you sometimes wish you hadn't started! It was hovering around freezing tonight after work, but there is a window of daylight to do a bit after work.

Got my painted gearbox brackets reinstalled, and the last of the gearbox mounts, weirdly for no apparent reason the lower two are odd, one is triple square and one is a not and bolt.

Engine back up to rear mounts and the jacks left in just in case can be wheeled out for the first time in months.




Left to do:
Waterpump (there a little play but no leak in existing)
Belt idler pulley bearings

Buzz off corrosion on sills and jack points and paint / cavity wax
Reinstall undertrays (new fixings) and brace bars
Reinstall front caliper and bleed brakes and clutch
REFILL WITH OIL (must not forget this)

Future work:
Install 997 shifter mechanism
Pluck up the courage to replace exhaust manifold
Install fire extinguisher
Deal with corrosion behind door striker
Discs and pads don't have loads left in them

Last edited by wasz on Tue Feb 13, 2018 11:40 pm; edited 1 time in total
 
  
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coullstar
Suzuka


Joined: 15 Sep 2015
Posts: 1217
Location: Aberdeen/Torphins


PostPosted: Tue Feb 13, 2018 11:30 pm    Post subject: Reply with quote

Good work, doing a lot of similar tidying bits as I just did. I'll be honest I'm not tackling clutch etc as don't have time/tools to do it. Fair effort.
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Tue Feb 13, 2018 11:35 pm    Post subject: Reply with quote

coullstar wrote:
Good work, doing a lot of similar tidying bits as I just did. I'll be honest I'm not tackling clutch etc as don't have time/tools to do it. Fair effort.


Thanks! I just blindly decided what the heck it can't be that hard can it, just unbolting old bits and bolting new bits up.

To be fair, removing and replacing the gearbox / clutch / flywheel was easy. Its just a big, heavy lump. I reckon I could have it done in a full day "next time". Like I say the only experience I have is of maintaining my own cars, previously the most extreme maintenance was removing and replacing a 306 gearbox when I borked the diff in it.

Its the faffing around with brake pipes and AOS that has sucked up loads of time.

Tools wise it has just been the usual 1/4" and 1/2" socket set, torque wrench I already had, a few specific bits and pieces that were cheap, brake flare tool £35, 2x decent trolley jacks, making the jack plate / camlock and borrowing Gixxer996's rms tool / bush installer.

I like to think I have saved thousands in labour. One member just paid £1800 for his brake lines alone.
 
  
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jond58
Silverstone


Joined: 19 Jun 2017
Posts: 118



PostPosted: Tue Feb 13, 2018 11:51 pm    Post subject: Reply with quote

Well done that man!! In the snow, laying under cars is no fun at all. I’m very fortunate that a friend is a classic car enthusiast/builder and another friend has a garage and mot station so I’ve access to lifts and indoors. I was moaning how cold it was last night doing my wife’s car brakes because the garage roller door was open!! Feel a bit guilty now!!!!
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Wed Feb 14, 2018 9:06 am    Post subject: Reply with quote

jond58 wrote:
Well done that man!! In the snow, laying under cars is no fun at all. I’m very fortunate that a friend is a classic car enthusiast/builder and another friend has a garage and mot station so I’ve access to lifts and indoors. I was moaning how cold it was last night doing my wife’s car brakes because the garage roller door was open!! Feel a bit guilty now!!!!


Ah its not so bad, just layer up and wear gloves!

Can't wait to drive it again now, the Freelander 2 I have borrowed is numb on my commute.




Driving
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My special order Vesuvious Charcoal 996 | Clutch, Fly RMS IMS AOS Job |
Steering Rack Hard Lines | Air Con Compressor / System
 
  
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eabeukes
Silverstone


Joined: 30 Jan 2018
Posts: 100


1999 Porsche 996 Carrera 2

PostPosted: Wed Feb 14, 2018 9:29 am    Post subject: Reply with quote

wasz wrote:

Future work:

Pluck up the courage to replace exhaust manifold


I recently had my manifolds replaced and kept the old ones - if you ever need to borrow the old mounts as a guide for drilling those nasty bolts PM me!
 
  
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 7784
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Wed Feb 14, 2018 11:52 am    Post subject: Reply with quote

I remember some years ago doing a head gasket on a Rover 214, it was a very cold breezy day and I was working on my parents drive. It started snowing half way through the job and my left sleeve was covered in snow.

After I completed the job I found out the water that had been coming from the exhaust hadn't stopped and it was actually the catalytic converter NOT the head gasket. Mad Mad Mad frustrated frustrated frustrated
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Fri Feb 16, 2018 1:52 pm    Post subject: Reply with quote

infrasilver wrote:
I remember some years ago doing a head gasket on a Rover 214, it was a very cold breezy day and I was working on my parents drive. It started snowing half way through the job and my left sleeve was covered in snow.

After I completed the job I found out the water that had been coming from the exhaust hadn't stopped and it was actually the catalytic converter NOT the head gasket. Mad Mad Mad frustrated frustrated frustrated


Character building!!

eabeukes wrote:
I recently had my manifolds replaced and kept the old ones - if you ever need to borrow the old mounts as a guide for drilling those nasty bolts PM me!


Thanks for the kind offer! Although I hear there is a jig available to do this, I'm hoping I can borrow one when the time comes.

How long did it take you to drill your out? How many studs came out?


I'm in £1000 in parts so far this job. Ouch.

However I just checked the OPC price for flywheel alone. £1005 inc vat. So I have good value really.....so I tell myself.
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Steering Rack Hard Lines | Air Con Compressor / System

Last edited by wasz on Fri Feb 16, 2018 2:02 pm; edited 3 times in total
 
  
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eabeukes
Silverstone


Joined: 30 Jan 2018
Posts: 100


1999 Porsche 996 Carrera 2

PostPosted: Fri Feb 16, 2018 1:56 pm    Post subject: Reply with quote

wasz wrote:


Thanks for the kind offer! Although I hear there is a jig available to do this, I'm hoping I can borrow one when the time comes.

How long did it take you to drill your out? How many studs came out?


Managed to get all bar one out normally (penetrating oil every few hours for the 48 hours prior to starting the job, Freeze spray on them to shrink) but the last one a local chap did for me in under an hour.

The Stomski jig is available to rent or purchase (I think theyre north of £300) hence keeping my headers just in case - apparently its just as easy to use these as a DIY jig
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Fri Feb 16, 2018 1:57 pm    Post subject: Reply with quote

eabeukes wrote:
wasz wrote:


Thanks for the kind offer! Although I hear there is a jig available to do this, I'm hoping I can borrow one when the time comes.

How long did it take you to drill your out? How many studs came out?


Managed to get all bar one out normally (penetrating oil every few hours for the 48 hours prior to starting the job, Freeze spray on them to shrink) but the last one a local chap did for me in under an hour.

The Stomski jig is available to rent or purchase (I think theyre north of £300) hence keeping my headers just in case - apparently its just as easy to use these as a DIY jig


What did yours look like to start with? Blobs or bolts? I might well be in touch!

Cheers.
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Steering Rack Hard Lines | Air Con Compressor / System
 
  
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eabeukes
Silverstone


Joined: 30 Jan 2018
Posts: 100


1999 Porsche 996 Carrera 2

PostPosted: Fri Feb 16, 2018 2:18 pm    Post subject: Reply with quote

wasz wrote:


What did yours look like to start with? Blobs or bolts? I might well be in touch!

Cheers.


Bit of both - feel free to PM me if you want them.
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Wed Feb 21, 2018 9:37 am    Post subject: Reply with quote

Righto,

I bled my brakes and clutch yesterday with my gunsons pressure bleeder. No leaks.

I checked my water pump, seems to be smooth and no play so am leaving that for another day.

However I had a close look at discs and pads. With the result I came in the house and ordered:

Full set of Textar pads (via eBay)
Full set of Discs and handbrake shoes (via autodoc)

I will also need new rear tyres soonish.....
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My special order Vesuvious Charcoal 996 | Clutch, Fly RMS IMS AOS Job |
Steering Rack Hard Lines | Air Con Compressor / System
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2586


1999 Porsche 996 Carrera 2

PostPosted: Wed Feb 21, 2018 8:37 pm    Post subject: Reply with quote

Still plugging away at this. On the home straight now. Might get it taxed in March....

I hooked up the gear cables and bolted up the axles.

Left side rear sill end after a poke with a screwdriver:



Hmmm right side is worse:



Buzzed off with a knot wheel in the grinder:




Porsche underseal is very tenacious stuff, even when water has got under and rusted the metal. See the sill end around the jack point is a little, erm fragmented - this was doused in mud held by the plastic trim. Still solid higher up though.

Doused in Phosphoric acid



Time for POR15 tomorrow, then loads of cavity wax for inside the sills.

Seriously everyone, remove these rear ward plastic covers, check for rust, pop your sill end caps out and douse in cavity wax before its too late!
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