Newbie With The Tranny Out, What Should I All Do?

[adamaborchardt]

I have a 2002 Porsche Boxster 986 with 58K miles. 5-speed manual.
I've always wanted to really get deep into working on a car so in the past week or so I pulled the tranny.
I've followed the Bently manual step by step. Pretty good manual.

I've got the clutch off and the flywheel too.

Link to pictures here: https://drive.google.com/folderview?id=0B6h7jVQgaK3BbS1HSjNqb1RCZWM&usp=sharing

I'm planning to call tomorrow and order some parts. It's pretty obvious the RMS is leaking so I'll order whatever is needed for that. I'm guessing I should probably dive a bit deeper into the fun and do the IMSB while I'm here.

Also going to do an AOS. Been getting the occasional puff of smoke and much of the engine area has a thin coating of oil on it (around AOS and intake tubing especially).

The things I'm wondering about:
1. Replacing exhaust manifold bolts with studs. Is this worth it?
1a. I do plan on replacing the exhaust system soon anyways with stainless.
2. My dual-mass flywheel has a tiny bit of freeplay. But it does spring back when twisted and doesn't torque too far. Will it be alright?
3. I know, I know....the clutch kit. But $750 is really steep. I've only felt minor chatter before when taking off in first and i figured this was due to oil leaking around the RMS/IMS onto the flywheel/clutch. Based on the pictures, think I'm good for a while yet?

Any other random advice is highly appreciated!

[JFP in PA]

Originally Posted by adamaborchardt

I have a 2002 Porsche Boxster 986 with 58K miles. 5-speed manual.
I've always wanted to really get deep into working on a car so in the past week or so I pulled the tranny.
I've followed the Bently manual step by step. Pretty good manual.

I've got the clutch off and the flywheel too.

Link to pictures here: https://drive.google.com/folderview?id=0B6h7jVQgaK3BbS1HSjNqb1RCZWM&usp=sharing

I'm planning to call tomorrow and order some parts. It's pretty obvious the RMS is leaking so I'll order whatever is needed for that. I'm guessing I should probably dive a bit deeper into the fun and do the IMSB while I'm here.

Also going to do an AOS. Been getting the occasional puff of smoke and much of the engine area has a thin coating of oil on it (around AOS and intake tubing especially).

The things I'm wondering about:
1. Replacing exhaust manifold bolts with studs. Is this worth it?
1a. I do plan on replacing the exhaust system soon anyways with stainless.
2. My dual-mass flywheel has a tiny bit of freeplay. But it does spring back when twisted and doesn't torque too far. Will it be alright?
3. I know, I know....the clutch kit. But $750 is really steep. I've only felt minor chatter before when taking off in first and i figured this was due to oil leaking around the RMS/IMS onto the flywheel/clutch. Based on the pictures, think I'm good for a while yet?

Any other random advice is highly appreciated!

To correctly test the flywheel: http://www.pelicanparts.com/techarticles/Boxster_Tech/44-TRANS-Clutch/DualFlywheelTechBulletin.pdf

Replace the clutch and throw out bearing. First of all, you have had an oil leak, some of which has probably already gotten on the disc, which will shorten its life. Unless you want to do this all over again in the near future, do it now. Shop around on the parts, you can do much better than that price.

Unless you plan to add headers, leave the manifolds alone; otherwise you are just asking for more grief.

[adamaborchardt]

I actually am planning on a full exhaust system next. Headers included.
I didn't have any manifold bolts snap and currently have the exhaust manifolds removed. Since I already have them out I figured studs might not be a bad move. I feel as though the threading in the block will not hold up well to repeated removal and reinstall of the manifolds.
But I'm a newbie and if I'm wrong I'm happy to be corrected.

[adamaborchardt]

Thanks JFP. I've also benefited a lot from your posts all over the various 986 forums.