Disassembly Done ... Time To Rebuild 3.0

[2jmotorsports]

Subscribed. Subbed all the 3.0 L rebuild threads.

Also good luck!

[arbita1]

Thanks.

Picked up my polished crankshaft yesterday. I'll post some pics later. Now I am waiting on the replacement wrist pin bushings to be delivered and then I will drop my rods off next to be re-bushed.

I'm pretty psyched. Yesterday when I was at the machine shop, he showed me two sets of 911 heads that he was working on. This is not a Porsche specific shop and I had only planned on giving him stuff that was more generic (crank, rods, cleaning, etc.) I told him I didn't realize he did these and he told me they do them and have been getting a lot for some reason lately. And his price was in line with other shops who do this. I was dreading having to pack up my heads and ship them. Now I think I can drop everything off with him. Glad I stumbled upon this yesterday.

[arbita1]

Progress has been super slow. Machine shop took forever with my rods. But I started to get stuff back and hopefully now will have some progress.

Crankshaft micropolished


Rods rebushed


Case hot tanked


Cam towers hot tanked


One problem. When I removed the oil pressure relief bolts and springs I didn't take out the piston piece inside. One fell out so the shop found it but the other one got hot tanked inside. It's stuck now. Any ideas on how to remove? It's the one in the right side case.





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[gtc]

Magnet?

[arbita1]

Apparently there was a part in Wayne's book that tells you to make sure you get the Pistons out before you hot tank your case as they will get stuck in there. Oops. I had to pop it out through the passage on the other side. I couldn't find anything to fit in there and then used my sons target arrow from his bow set to knock it out.


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[cgarr]

A 1/4 pipe tap works good to grab those pistons too:

[Trackrash]

A strong pair of circlip pliers works.

[Forrestkhaag]

This thread is most helpful in gaining insight into my 3.0 tear down and subsequent build. Thanks for the pictures and conversations from all involved. Here we go!

[arbita1]

Some progress...finally. Got the crankshaft together. On to case assembly now.




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[Forrestkhaag]

A thing of beauty!

[jess p]

Nice job. I have an 81 911 sc that I'm just started the same process. Ordered
the P 202 and 203 tools. That's what's holding me back

[arbita1]

Trying to figure out all the locations that require epoxy It's a little hard to tell from the photos in the book. Is this one?



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[Mark Henry]

Yes, but take care not to over do it as the fan sits tight against it.

[arbita1]

I was making progress today.





But then.



I'm hoping heat and a stud remover will get this out.

[mikedsilva]

Wow...
surprised that stud broke off.. the oil pump nuts aren't torqued that tight are they?

I'm doing a 964 engine at the moment too..
When you got your case back from being hot tanked, what other prep did you do to get it super clean?
Also, did you removed the sealant from the flanges or did the shop do that for you?
Cheers
Mike

[al lkosmal]

I've not seen one of those break before.....but a good stud remover, heat and PB Blaster are your your friends.

[arbita1]

Originally Posted by mikedsilva

Wow...
surprised that stud broke off.. the oil pump nuts aren't torqued that tight are they?

I'm doing a 964 engine at the moment too..
When you got your case back from being hot tanked, what other prep did you do to get it super clean?
Also, did you removed the sealant from the flanges or did the shop do that for you?
Cheers
Mike

I used carb cleaning and shop towels. Followed by isopropyl alcohol with Kim wipes. The hot tank took off most of the old sealant. What was left I used a scotch Brite pad and carb cleaner to remove the rest. Also I found that goof off and a razor blade works well for removing stuck gaskets.

[arbita1]

Originally Posted by al lkosmal

I've seen one of those break before.....but a good stud remover, heat and PB Blaster are your your friends.

For some reason it wouldn't click on the torque wrench so I kept going and then snap.

[arbita1]

So the good news is this stud did not put up any fight. A little pb blaster and a stud remover. Didn't even have to use heat. Now waiting for the new stud. The PET shows the stud as a m8x20. But when I enter the part number it comes up as a m8x37. Not sure which is right.


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[cgarr]

Some show grip length after installed and some parts list show over all length.


I think pelican shows overall length at least they do with exhaust studs

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