The never ending Winter project project. Now very depressed.

[bit]

Hi Guys,

Further to my Winter Projects and chronicals on my 1980SC;

So I bought a Porsche (very long) opinions please
My Winter Projects Update - like usual, long
My Winter Projects Update 2 (long again)
My Winter Projects Update 3 (long again, but it's almost over)

The Chain tensioners are installed.
The 1st gear Syncro and dogteeth are repaired.
All vacuum leaks fixed.
Cam timing performed.
All covers replaced.
Oil breather lines replaced.
Engine and tranny re-assembled and re-installed.
New hard oil line for SSI's installed.
All components reconnected to engine.
SSI exhaust and Dansk muffler installed.

I have now fully buttoned up my car and completely detailed the vehicle, and insured it for Summer. YIPPEE!! HOWEVER. after just one day of driving it and experiencing the new upgrades (wow what upgrades), DISASTER STRIKES! Tonights post was to for me to provide some closure to this years winter projects but it is not to be. I let a friend try my car and I had just adjusted the clutch cable. I guess when he pressed the clutch pedal down hard, it pulled the throwout bearing off of the pressure plate. Damn, damn, damn. The clutch will no longer engage. Now I need to do an engine drop this weekend again to fix this. I feel like crying.

Here's some picks of the car and the new goods.

I feel so depressed.

Here's a pick of the engine and tranny all ready to go back in. Stu and I set the CAM timing TDC overlap to 1.6mm (Euro spec) and primed the engine with oil to pump up the tensioners. We found and replaced one tensioner that would not harden up (sure glad he convinced me to prime them first). I put some Swepco 201 into the gearbox (what stinky stuff eh, and it's blue?!?).




Here's the engine going back in. My dad and I did the deed but Stu lent us the jack and cage to hold the engine in place to re-insert (plus many other tools that halped greatly along the way).





Stu came by and did a double check to make sure that everthing was installed and connected correctly, and helped me re-install the clutch, halfshafts and SSI exhaust/Dansk Muffler.




And here is the final result.





When we first turned it over, it took about 5 seconds for it to start right up. Amazing. the engine was out and dry for 2 months and it fired up almost instantly. Very good sign, and high 5s all around.

The first lesson I learned was that the voltage regulator needs to be plugged in. Doh! The battery wasn't charging and the Alternator red light would not come on when the key was in the On position. I had the alternator completely removed, from the engine (which really is not an easy task once it is installed) rechecking all the connections and double checking if the alternator was good. Everything looked great. Eventually we realized that the VR was disconnected. Ooops. 3 hours wasted there.

Stu adjusted the air/fuel mixture, performed the timing advance at 6000rpm to 25 degrees (he figures conservatively) and set/verified that the timing.

All I can say is WOW. My car ran AWESOME!! It was a wonderful 24 hours!! I can now fully appreciate what a Porsche is. Cloud 9 man!! It was almost terrifying!! BUT it only lasted a day.

and then today....... It broke........ I have to take the engine again out on Saturday for my clutch problem. Probably do just an engine drop and leave the tranny in place (unless something more needs doing).

I am just so tired and aching, plus I have a real job and can't spend all my time on the car. I'm just wiped right now (3am as I type here). I really really want to get it roadworthy.

I am as depressed right now, as I was elated yesterday.

More to come, I'm sure.

My saga continues.

Regards,

.Steven
1980 911SC

[Doug Steinel]

Steven,

The engine looks great. Don't fret about having to go back a step and fix the clutch. It nothing next to what you have done already. Just expect that we DIYers should expect to have these problems. Be happy that the engine runs so fine. Any oil leaks?

Doug

[Wayne 962]

You've got an extra synchro sitting on your transmission. Hopefully that didn't have to go inside!

Seriously though, check the following prior to dropping the engine:

- Check the cable, they can snap
- Check the helper spring and clutch throw-out mechanism
- Check the pedal cluster
- Remove the helper spring and see if you have any force on the pressure plate -

Good luck - don't panic, the engine looks great!

-Wayne

[Bob's Flat-Six]

Steven,
When I started reading your thread I tought you were going to say the car caught on fire or something really BAD.
Cheer up you'll be enjoying your 80 SC ( nice year by the way) before you know it.

Maybe it's a problem that can be fixed without an engine drop? clutch cable or?

Anyway beautiful work, It will be right before you know it.

[Thomas Owen]

Get an early start on Saturday and you will be driving it that night! Be cautious and don't cut corners on the engine drop (jack stands and blocks, etc.). Buy extra parts if you need them and whatever is left on Monday, return it.
You have done a great job so far -
Good luck

[subdewd]

Looking at your engine makes me want to cry,,beautiful!!

[blackbird225]

I second taht commotion. Looking at your engine makes me wnat to cry... sniff sniff.
Stunningly beautiful. If Wayne says don't worry, don't worry. I mean that guy wrote the book on this, literally.

Cheers to your project.

How much did it set you back?

Michael

[jyl]

You're really, really close. One full day of work. You can do it!

[JackT]

I wish I was in your situation. Your engine looks great and you have a great setup. When the clutch is fixed there will probably be nothing else to do to your car. Then you will be bored looking for something else to do.

[Rot 911]

Steven, did you read my thread a couple of weeks ago where I reinstalled my rebuilt engine (that I spent all winter rebuilding!) and left the starter ring gear off the pressure plate? I truly do feel your pain. On the plus side, I got lots of moral support from the guys on this board. It was amazing how quickly I was able to pull the engine (without pulling the tranny) and get that gear in place. It really does go much quicker the second time. Hang in there!

[Tim Walsh]

At least you don't have to tear the motor back down. I knew a guy who built up a very nice twin plug race motor.. only problem? The crankshaft gear hadn't been swapped for the twin plug gear.. the whole motor had to be torn down to replace the gear after the whole motor was assembled.. THAT's not fun.

[osidak]

Could be a broken fork.

[Rick Lee]

Dude, if that's the worst thing that happened in this whole process, then you're doing just fine. You have an afternoon's worth of work before you fire up and drive what you already know is a purring engine. Try installing the wrong size spring plate (in a freezing cold garage), then finding out it's for a short wheel base 911, reinstalling the old one just to get the wheels back on to roll out of the garage to wait another week for the right spring plates to arrive and the having the wrong fan housing sent to you 3 times. Makes a two weekend project into a two month nightmare.

[onewhippedpuppy]

VERY nicely detailed engine! The end is in sight, don't give up now! Like Bob said, I thought you were going to say it caught on fire, or was run over by an 18-wheeler. Kurt had a similar problem, and he's already back on the road. I had the exact same problem with my T, it was the clutch release fork pivot pin, SCs have a totally different system, I'm sure you'll find it's somthing simple. In a few days you'll be on the road, and will have totally forgotten about all this, now get out there and get to work!

[rcwaldo]

At least you wont get dirty r&r'ing your engine/gbx as that thing looks really clean!

Get an early start Sat Morning, maybe even start this week a little at a time disconnecting stuff. You'll be done in no time!!

Looks great!!

Chris

[john walker's workshop]

kind of unusual for the t/o bearing to pull out of the pressure plate, unless it wasn't attached properly.

[vash]

that motor is nice! dont even worry about dropping the motor again, that is a tiny detail you will laugh about later.

[bit]

Hi guys,

Thanks for your support. I spoke with my mechanic friend and he thinks that the throwout fork brobably broke or split. He doesnt's think that my theory of the bearing coming off the plate is plausible.

Wayne - I checked the clutch cable and the pedal cluster and they both are fine. I can see that the helper spring will not engage the the throwout shaft, there appers to be about a 3mm gap between the end of the bolt and the place where it should be pushing. Adjustments won't help this problem. Here's a pic of my problem. The gap I'm pointing at should not be there.



Blackbird - the whole update cost me about $3500 cdn. (about $2500 US??) for the SSI Exhaust and muff and oil line, tensioners, powdercoating, clutchdisc and some other misc items.

KurtV - I read you posts buddy, and I really feel for you. When I realized that the engine had to come out, I thought of your situation immeditely. I also remembered how I did not want to be in the same predicament as you. Some day we'lll both laff off our problem (sniff, as I wipe the tear of agony away).

I guess this is the life if a DIYer. I'll update you guys on my progress.

So how many of you out there have seen a fork break? Stu says this is a common thing that he's seen before.

Take care guys,

.Steven
1980 911SC