Things to do when the engine is out?
 

I had a very experienced air-cooled tech drive my '84, to give me an opinion on the shifting. I've previously installed a Wevo coupler, which improved it. I've had multiple later cars with G50's and a couple of 930's with 4 speeds which shifted better than my car. This being my first 5-speed 915 I wasn't sure exactly how it should shift, but first gear just seemed like it often needed double clutching when stopped to slip in cleanly. The tech said he thought the first synchro was probably on its last legs, and second was soft. The good news is that he said everything else felt good this was likely nothing resembling a total rebuild. I want to stay ahead of this and just address it now instead of risking damage to the gears themselves.

Seeing as the engine is going to come out there are a few other things that I've got on my list to address. I'll probably do the clutch. Upgrade a/c system with barrier hoses and possibly a few other things is on the list. Replacing any original fuel lines ('84 Targa), and address anything that might show signs of leaking (though oil tubes were replaced within the year and only 2k ago).

Is there anything else from a mechanical standpoint that it makes sense to do while I'm at it? How about cosmetic stuff? My fan doesn't look great, so I was thinking of refinishing it and the housing.

You want to address all the stuff in the tunnel (even if just for peace of mind):

- Fuel lines (feed and return)

- Battery cable condition and insulation

- Throttle linkage bushings

I'm sure I'm missing something; others will chime in.

Rear suspension is a lot easier with the engine out...

Anything needed for the engine? Much easier when it's out of the car.

Other stuff: Clean up the engine bay. Replace the rubber skirting if needed. Check / clean-up the heater boxes.

Look up TOD the triangle on top of the motor Oil pressure sensor ,Thermostat O rings, crankcase ventilation gasket replacement. Triangle of death oil leaks, and replace oil cooler gaskets and cleaning.

Do a valve adjustment and replace the plugs while it is easy.

Remove sound pad over the engine.
Clean up engine compartment, usually lots of oil on RH side from oil changes and goof ups filling oil.
Light weight stater.
SSI heat exchangers and dansk muffler
Check and rebuild distributor if needed
Upgrade transmission and engine mounts to later model

Inspect/Replace vacuum lines for fuel injection, brake booster, oil tank.

Pull out the steering rack and dismantle it. It may well need grease and new bearings, not a difficult job. Having it out will make your fuel line replacement much easier.

The car has just had a full service at the end of last year right before I bought it, and only has 45k on it (bought it with 43k). Valves adjustment, all belts, sound pad, lots of lines, oil tubes, etc. have all just been done. I've just done an M&K cat bypass/sport pipe/SW chip, so nothing to do there. Pads/rotors and brake lines have just been done too. Fuel lines and changing to a/c barrier hoses (when I asked about an a/c upgrade) were the only things the tech suggested, and he told me the a/c compressor looks brand new (R134). Motor and transmission mounts are good suggestions. I put on a new engine decklid seal when I got the car. Definitely plan on a major detailing with the motor out. Thanks for all the input!

Any reason why this would be necessary at 45k?

This is what i did on my now sold and enjoyed by the next owner 89

https://forums.pelicanparts.com/porsche-911-technical-forum/947830-while-youre-there-clutch-job-gone-crazy.html