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944 89 Engine, gearbox transplant...
https://forums.tipec.net/viewtopic.php?f=25&t=24357		 Page 1 of 18
Author:  Crank Case [ Tue Apr 07, 2020 4:52 pm ]
Post subject:  944 89 Engine, gearbox transplant...
It's a long story...

But i'm not going to bore you with the details. I managed to procure a 2.7 engine from Steve Strange - verified miles of 72k, compression and leak down A1. I 'rebuilt' most of it bar replacing the head gasket as it was such good compression etc, I thought I would leave it.
My gearbox was making very pinion bearing noises as well as other grinds and so not only did I get the engine, I also got the box off the same donor car and ECU for a very good price.
I changed belts, water pump, all the gaskets, oil sender unit, re-sealed balance shaft covers... the list goes on and on. I also replaced almost all bolts with stainless steel. I enameled the rocker cover too.
Had the injectors refurbed and I also have a refurbed AFM from Frazer parts to put on the engine.

I also have a clutch kit.

So this marathon actually started November 2018 when I did the engine and now, given that I have more time (and energy) than any previous occasion, it's time to take the old engine out.

(it will be for sale if anyone wants it cheap).

Image

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T'was lovely doing the sump gasket with the engine on a stand and upside down. I used some bolts and washers, a touch of Wynn's gasket maker and tacked the f*cker down and then fitted the sump once the gasket maker was dry.

So, I have taken off everything 'north' on the engine for extraction plus exhaust manifold and now it's time to move 'south, and start shifting wishbones, cross members and all that malarkey.

Image

End of day 2. This is going to be a long haul.
Author:  Waylander [ Tue Apr 07, 2020 5:10 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Bit Jeremy Beadle Rob, game for a laugh :D

I’m sure it will all be fine
Author:  Crank Case [ Tue Apr 07, 2020 5:25 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Err... it would be if it had the 'laugh' bit.

...and every minute spent on it, i'm thinking 'how much have I bitten off and can I chew it?'.
Author:  51rider [ Tue Apr 07, 2020 5:56 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
T'was lovely doing the sump gasket with the engine on a stand and upside down.

I'll bet it was! Having recently done mine in the traditional orientation, that must have been an absolute breeze!
Author:  Waylander [ Tue Apr 07, 2020 6:07 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Crank Case wrote:
Err... it would be if it had the 'laugh' bit.

...and every minute spent on it, i'm thinking 'how much have I bitten off and can I chew it?'.



All depends on your outlook,

Wish I never started this, can’t be assed to get it done

Or

This is a lot of work but I’m learning and I will finish it and be proud of my achievement!

Just ask 51rider for a moral boost, he’s been at it just as long, but this covid crap has stopped me helping him
Author:  Crank Case [ Tue Apr 07, 2020 9:24 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Waylander wrote:
Crank Case wrote:
Err... it would be if it had the 'laugh' bit.

...and every minute spent on it, i'm thinking 'how much have I bitten off and can I chew it?'.



All depends on your outlook,

Wish I never started this, can’t be assed to get it done

Or

This is a lot of work but I’m learning and I will finish it and be proud of my achievement!

Just ask 51rider for a moral boost, he’s been at it just as long, but this covid crap has stopped me helping him


It's definitely the latter - i'll really know my car inside out.
..and when I come to do the split on the external drive shaft boot on my 997, it will be a breeze in comparison.

I must admit to a bit of cheating though, I bought myself an early birthday present... a Dewalt Cordless impact driver :D
Right you cross member bolts etc, i'm a comin'...

Can I recommend Inotec deblocker - the preferred deblocker of old, gentleman Porsche's. You know the ones' - seized frikkin bolt one's.
Author:  51rider [ Tue Apr 07, 2020 10:04 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Impact driver!! Bloody Luxury!
Deep socket, extension piece and a 3ft breaker bar with Waylander on the other end- bolts didn't stand a chance :lol:
Author:  Crank Case [ Tue Apr 07, 2020 10:19 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
51rider wrote:
Impact driver!! Bloody Luxury!
Deep socket, extension piece and a 3ft breaker bar with Waylander on the other end- bolts didn't stand a chance :lol:


I have a 2.6ft breaker bar and some long tubes of metal...

But oh that luxury. Thing is, it's a bit fierce and i'll still be doing them up mainly by hand and using a torque wrench.
Author:  Waylander [ Wed Apr 08, 2020 6:38 am ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
That was the only thing that undid the rear hub nuts when I did the wheel bearings, a DeWalt impact driver 550nm,

I had already broken 3 breaker bars before I managed to borrow one


Does make life sort of easier, just don’t have on do up by mistake!
Author:  Crank Case [ Wed Apr 08, 2020 8:54 am ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
I have a long hollow bar that fits over the breaker bar...

I haven't used it (on this job) yet but that's a just matter of time.
I once had to go into a local tyre fitters as I had a puncture on the Sprinter I was driving.
He broke a Snap on breaker bar on a wheel stud.
He moaned a lot but I was thinking that Snap on have a lifetime warranty so he should have got a new one, so what was the problem?

Anyway, this isn't getting an engine out.
Author:  Waylander [ Wed Apr 08, 2020 10:03 am ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Crank Case wrote:
I have a long hollow bar that fits over the breaker bar...

I haven't used it (on this job) yet but that's a just matter of time.
I once had to go into a local tyre fitters as I had a puncture on the Sprinter I was driving.
He broke a Snap on breaker bar on a wheel stud.
He moaned a lot but I was thinking that Snap on have a lifetime warranty so he should have got a new one, so what was the problem?

Anyway, this isn't getting an engine out.



the rear hub nuts are 389ft/lbs or 500nm tight and not moved for 28 years, and i'm lead to believe that beetle ones are even tighter,

I took my car to the local truck workshop with the centre caps out of the wheels and dropped the guys a drink to torque them back up for me, 3/4 torque wrench and socket
Author:  Crank Case [ Wed Apr 08, 2020 5:49 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Didn't get too much done today, though borrowed a hoist

Image

...made up a trolley to place the engine on, which should be out tomorrow, i've only the cross member to do (sort of):

Image

...this pic is for Waylander and 51Rider. I've called the extension bar 'The Waylander':

Image

Not much to do before the old lump comes out:

Image

Decided that the clutch slave cylinder was looking a bit Ropey, so ordered a new one.
Steering rod ends gave me jip so I sorted them with the angle grinder and they're on order too.
Author:  51rider [ Wed Apr 08, 2020 6:15 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
Nice persuader! :wink:
Author:  Crank Case [ Wed Apr 08, 2020 7:47 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
...added steering rack bellows to the shopping list and new high tensile bolts for the wishbones. I have a raft of SS in M6, M8, M10 nust and bolts.

I'm not envisaging too much extra expenditure here as I have done everything that needs doing to the engine, I have a Sachs clutch kit, The upper semi solid gearbox mount is new, i'll need gearbox oil, there's no play in the back end (me thinks)..., the exhaust is all SS kindly done by some great boys in Prestwick at a very good price. Bar the manifold, it's on 3 easy to extract sections, I bought the machined SS gear linkage and gear lever mechanisms off JMG Porsche - they're a work of art and it's fit and forget. Watched a few vids where they made shims to fit a standard linkage - sod that.

Oh and that impact driver... (where I could get it in), luverly.

Torque tube bolts were a bit of a pig, took clutch slave out to access the top bolt ('North West', 10 o'clock(?) looking from underneath towards the front end of the car), couldn't get the impact driver in there...

The power steering fluid was well past it's sell by date. Not sure I get much assistance off the PSP. I guess new oil will help but I kind of like the steering the way it is; nice and direct.

I'm waffling, best go.
Author:  Waylander [ Wed Apr 08, 2020 8:08 pm ]
Post subject:  Re: 944 89 Engine, gearbox transplant...
I would buy a new PAS tank, they have a non cleanable filter in them, after all these years might be worth it, got mine from GSF think it was about £13, but soon after the high pressure hose went pop, bought a new one from a power steering place for 85 quid, Porsche want £375 for the same pipe

Now the steering is direct, light and full of feel and it does not groan anymore
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