Monday's project=Remove thermal reactors. Any surprises??
 

Hey guys,

I have a 76S with the dreaded thermal reactors and im about to remove all of it and replace with the heat exchangers and everything from a 74. Other than breaking bolts loose, are there any surprises I might run into during this swap?? I wont be able to buy parts till tuesday but for now I have ALL related exhaust parts. Bolts, gaskets and all pipes with muffler.
Thanks
Nathan

You appear to be aware of the rusted nut - broken exhaust stud possibilities. The studs on the mid-year cars are even more problematic due to their reduced cross-sections. Serious heat on the nuts (cherry to orange red color) is your friend. Then new nuts and anti-seize paste on the stud threads upon reassembly. Note the air injectors and their air feed manifold and portions of the EGR system will need to also come off to fit on the early exhaust system, You'll need to make/obtain a blank off plate for the EGR valve, a plug for the port on the muffler and 6 plugs for the air injector ports in the heads.

I have attached four links that show the removal of the 3-1 headers off my '76 (the thermal reactors had been previously removed by a PO and replaced with 3-1's) and the installation of SSI's.


http://forums.pelicanparts.com/porsche-911-technical-forum/151353-ssis-onto-76s-step-1-a.html?highlight=SSIs

http://forums.pelicanparts.com/porsche-911-technical-forum/152148-ssis-onto-76s-step-2-a.html?highlight=SSIs

http://forums.pelicanparts.com/porsche-911-technical-forum/153506-ssis-onto-76s-step-3-a.html?highlight=SSIs

http://forums.pelicanparts.com/porsche-911-technical-forum/154629-ssis-onto-76s-finish.html?highlight=SSIs

Yesterday I removed all the exhaust componants with 2 broken studs, the rest came out with EXTREME heat. I also found very leaky oil tubes and am going to do a valve adjustment and replace all valve cover gaskets. I have a few leaks but if I have oil dripping out of an oit tube while the car is dead cold, I can only imagine how fast its coming out hot.
Any advice is accepted based on these pics.
I have a leak out of these places:
I dont know what these goop is around that thing above the drain plug but it leaks.
I seem to have a leak around the area under the tranny or at least I find a lot of oil down there after a few long drives but it may not be coming from there but if it was, where would be a likly place to look?
Thankyou


http://forums.pelicanparts.com/uploa...1180541183.jpg http://forums.pelicanparts.com/uploa...1180541229.jpg http://forums.pelicanparts.com/uploa...1180541308.jpg

the goobered nut on the side of the case generally means the stud is pulled. it will always leak unless you do a quick fix by tapping the case for a very short 10mm bolt with a sealing washer under it.

Well, This has been a HUGE job that i will finish tomorrow. I replaced the oil tubes, the oil lines are different from the thermal reactor cars to the heat exchanger cars, and 2 of the suds broke which I had to drill out. I have some pics.http://forums.pelicanparts.com/uploa...1180845683.jpg http://forums.pelicanparts.com/uploa...1180845711.jpg http://forums.pelicanparts.com/uploa...1180845770.jpg

Oil leaked out of the oil tubes with the engine stone cold, as well as the thing here in this pic. This is a closer shot of the above pic.
John Walkers Workshop-------Please explain what I do here in a little more detail

http://forums.pelicanparts.com/uploa...1180846081.jpg

I think that John is saying that you will remove that entire stud/ nut assembly, as the threads that it screws into have pulled out of the case, then you will tap the open hole you have left, and install a short bolt with a sealing washer. This is a great idea, as this is a common leak area, and you have to split the case to repair it, John is a genius

that's correct, except for the genius part. doesn't hurt anything for any future proper repair and no drilling required. just run a 10mm tap in about an inch and plug the leak with a short bolt and aluminum washer. don't get carried away on tightness, as it's still a soft mag case.