First Engine Drop, Lessons Learned... Long

[DaddyGlenn]

Several of months ago, I dropped the engine and transmission out of my ’78 SC for the first time. I started a thread on that project here: Here goes...1st Engine Drop

Being my first drop it was very educational. I’d like to share some of the things I learned along the way in this thread with the hopes of helping those who are contemplating their first foray into this area.

Dropping and engine and transmission out of one of these beloved cars is a defining moment in the life of a Porsche owner. It is a rite of passage. It elevates your status considerably. Most of us can change the oil. Many adjust their own valves. But pulling out the engine/transmission is a solid step above. You are elevated in knowledge and experience in one big step. Even if you are “as thick as a brick” and learn nothing, your status is raised in the eyes of those who have yet to rip the heart out of their cars simply because you have done it.

There are significant steps above this and I will write about those as I move my way up. But, you cannot skip over this step to earn greater status at the next levels. This is a big step and everything you have done to this point pales in comparison. You’ve worked on individual problem areas, touched one system or maybe two at a time. Now you will be seriously screwing around with at least half a dozen at the same time. I hope this thread will help your ascension.

First and foremost, yes, you CAN do it. And you can do it alone. In fact, I would recommend doing it alone. You’ll want someone with in screaming difference in case all your planning and preparation goes horribly wrong (which shouldn’t happen). By doing it yourself, you will learn more than watching someone else do it or even having an experienced person direct your actions. Not only will your mind be more involved but your eyes, ears, hands, back, legs, feet ,too. You will learn the feel of doing it right … and wrong.

Once you have decided to take the leap, go to school. Search this forum, read the steps in every book you can get your hands on. Find out what tools you will need and get what you don’t have. Don’t try to make do with something else just because you don’t have the proper tool. Unless you have found significant evidence on this forum that what you have will do the job, spend the money. There are usually many options. Find the one that fits you best. For example, in stead of buying a motorcycle jack, I build a dolly. (see the above mentioned thread for more on this)

If you don’t have it already, buy the Bentley’s book. It is invaluable. If you use the steps in this manual you won’t miss anything. The “101 projects..” book is a great book but not for your first drop. Don’t try the engine only. Consensus on this board is to drop engine and transmission together. Read the process in Bentley’s over and over. Then read it again. Now, close your eyes and do the steps in your mind.

Pilots understand the concept of “chair flying” where you sit in a chair and practice your flying procedures using your imagination to picture everything. Racers also use this technique to prepare for a race. Do the same for your engine drop. But do it differently than I did. Don’t lie in bed at night thinking about what needs to be done and what you might screw up. Schedule some time to yourself to sit and logically go through the steps. Close your eyes and see yourself first jacking up one side of the car, placing the jack stand then jacking up the other side of the car, etc. For every step, think about the tool you will use. What if I need more leverage? What if the head strips? What will come free when I remove this bolt? How heavy will it be? Will something leak out?

When you stop thinking of new ways the process can go wrong, you are ready. Pick a day, hang a “do not disturb sign” on the garage and go for it.

After learning that I COULD do it, I learned several other truths. Starting with:

Nuts and bolts will get stuck. If you haven’t learned from other projects, getting frozen hardware to release their grip requires a technique of patience and finesse not brut force and ignorance. Search this board for help. Just about every nut and bolt that can get stuck will and someone has written about it here. It may take heat, chemical warfare or a tool you never thought of using. My brut force and ignorance cost me and extra $35. I was lucky.

The next truth I learned is that you WILL forget something. So, when you think you have disconnected every hose, wire, cable or other gadget and are ready to lighten your car by over 500 pounds, just stop. Walk away for a minute or two. Then go back a double check each step. Trust yourself but … verify. Confession time – I forgot the oil hose from the oil cooler and had the engine half way down before figuring out why it wasn’t coming down straight.

Another truth – I don’t care how good and careful you are. You WILL drop something small where it should not be dropped. Plug each and every hole with a rag. I mean every hole and all the time. I pulled a rag out temporarily to gain more room to work and … you guessed it … washer in the intake. I was very lucky that the valve was closed and I could retrieve the washer easily. But jeeze that was close.

You are also not as brilliant as you think. You cannot remember where every nut and bolt came from. You need baggies and a sharpie. Label everything and take tons of pictures. I took a lot of pictures and wish I had taken more. You will forget to label something or the label will fall off. To butcher a phrase, a picture is worth a thousand labels.

You will also need your camera as soon as the engine is out. Every advancement in life requires proof that you have attained to right to that advancement. To officially advance to “engine dropper” status, you must have a picture like this.



When the engine and transmission are out, you can start your “while I’m in there list.” If you’re going to continue on to one of the higher levels such as “engine builder” or “transmission builder” My hat is off to you and my advice ends here. However, if you have a small list and corresponding small budget, pay close attention. Your list is too short and your budget is too small. One more time, your list is too short and your budget is too small. I’m not kidding. Unless you had someone else pull your engine recently and tell you everything that needs to be fixed your list will grow and with it, the impact to your wallet.

I had a short list of preventive maintenance and minor repair with a budget of a couple hundred dollars. I figured a couple of weekends of work then back on the road. WRONG!! Try 10 weeks and $1,700! And I discovered other issues that will force another engine drop and about $1,000 later this year.

Putting it back together…. Installation IS the reverse of removal. Everything applies. Study, plan, do, check then drive. And since you have touched everything before, it will be easier.

Good luck and have fun. It is worth the effort. You will know your car better and you'll stand taller.

Comments? Suggestions?

[Tom '74 911]

Glenn -
Thanks for the write-up. I've followed your thread from the beginning and am only just now starting to think about following your lead to do my first engine drop to chase a few leaks clean things up. I think your advice, "your list is too short and your budget is too small" is good. I'm a big "while I'm in here" kind of guy and I know if I wasn't careful, I could end up w/my entire engine in pieces and an empty or negative bank account - and spring is comming!

Your post and experience is a good confidence builder for me.

Thanks,
Tom

[holtjv]

Yes, you've inspired me to take the plunge. I WANT that rite of passage!

Jack

[jtfreels]

Thanks Glenn, I also read your thread from the beginning, it was a confidence builder.
So you guys think of me tomorrow. I'll be dropping my engine to find out whats wrong with the clutch. And then a couple of oil leaks to fix, and what to do about the engine sound pad its will probably fall out with then engine and then .........

[DaddyGlenn]

Thanks guys. I hope you will keep us posted on your adventures. I look forward to seeing your smiling face where your engine should be.

[redcoupe86]

I have a question about the engine drop, or should I say the engine stand.

In "visualizing" my engine drop I get a blank on how you get the engine from the dolly to inserting the connected engine bracket to the engine stand. What if the dolly can't raist the engine high enough to fit it into the stand? Is there a better way?

[DaddyGlenn]

Red,

I left it on the dolly and sat my happy butt on the ground. Granted everything got clean except the bottom of the engine but I figured I could clean that side when it was back in the car.

You could rent or borrow an engine hoist, though.

[yelcab1]

Originally posted by redcoupe86
I have a question about the engine drop, or should I say the engine stand.

In "visualizing" my engine drop I get a blank on how you get the engine from the dolly to inserting the connected engine bracket to the engine stand. What if the dolly can't raist the engine high enough to fit it into the stand? Is there a better way?

There are two methods:

1. Four friends with strong back will lift that baby right up. (neighbors will do)

2. Engine hoist, crane, lift, etc... makes it a one man job.

[TERRIBLEHONDO]

Glenn, I have to agree with the list and cost statements. I stayed more on budget than you did. But if I was a while I am in here guy I could have gone crazy with added detailing and parts that are showing wear. I felt with the ease of the engine pull I will just go back into it in the summer and do the clutch and some other things when I have saved up some up for the job. Maybe I can make mine look nice like yours then. I also emailed you on some cams I saw that you might be interested in for your summer project if you do not need the better grind.

[Tom '74 911]

Glenn -
A quick question about the dolly you made to roll the engine around once out of the car. I'm following your lead and making something similar. My question is: Did you put any kind of raised strip down the center to support the crankcase directly, or did you let the engine rest on the heat exchangers? I'm worried my slightly rusty HE's may end up worse for wear if forced to take on the full brunt. Curious as to what you did.

Thanks,
Tom

[sjf911]

I made a rough template of the engine bottom and formed 3/4" plywood (several layers glued together) for the engine to rest on on the dolly. As it turned out, the HE's were bad anyway.
Getting the engine on to the stand is the second most intimidating part of the process. I did the entire process solo but used a chain hoist (attached to a jack point in the ceiling) and leveling bar to raise the engine to the stand after the adapter was installed. I didn't want to risk injury to any of my friends.

[DaddyGlenn]

Originally posted by Tom '74 911
... Did you put any kind of raised strip down the center to support the crankcase directly, or did you let the engine rest on the heat exchangers? I'm worried my slightly rusty HE's may end up worse for wear if forced to take on the full brunt. Curious as to what you did.

Thanks,
Tom

Tom,

I let it rest right on the HE's. I have SSIs and they are about the same level as the bottom of the crankcase. The wider you distribute the weight, the more stable it will be. If I were you, I would be prepared to shim a bit under the crankcase to even out the weight distribution.

Good luck and keep us posted along the way.

[Tom '74 911]

Originally posted by DaddyGlenn
Tom,

I let it rest right on the HE's. I have SSIs and they are about the same level as the bottom of the crankcase. The wider you distribute the weight, the more stable it will be. If I were you, I would be prepared to shim a bit under the crankcase to even out the weight distribution.

Good luck and keep us posted along the way.

Thanks for the info Glenn. I think I'll put a few shims on the dolly, maybe w/a hole cut for oil drain plug and something around the clutch arm.
Thanks,

Tom

[Airkooled82]

Well, i didnt learn much watching my new mechanic, but fun to watch..hahaha..