Great! Looking forward to pictures from the photo shoot. And I should also compliment you for all the documentation you have done while restoring your car, its fantastic.

And you are right about the 911 in the Le Mans movie. It is pretty nice but it isn't the Rat ;)
Your 911 is soon becoming more famous than Steve McQueens, and maybe even more valuable to:D

be sure to have someone standing by with a cell phone during engine R&R

also a lot easier with 2 guys working on it

Thanks for the kind words. Glad to know that I am inspiring!! I wish you lived closer too as I can always use as much help as possible. If you are ever down this way shoot me a PM.

Thanks for the encouragement. I am certainly going to need it to clean up and rebuild my nasty axles;)

It is indeed not the Rat. More famous and more valuable than the McQueen 911 would certainly be nice:D

Hi Randy,

Why exactly do I need a cell phone to drop an engine? Pretty sure the factory or the racing teams did not use cell phones for an engine drop;) It would have been really difficult to do this by myself so I followed Wayne's advice from the 101 book and made sure Peter was there to help me. Thanks again Pete:D

Here is some progress from day 3 of the clutch replacement adventure. Today I was able to get the flywheel off and replace the throwout bearing.

Flywheel lock in place

http://forums.pelicanparts.com/uploa...1374884246.jpg

Here are a few close up pictures of the flywheel. I am hoping that it can be machined and will take it to a machine shop on Monday. Does anybody have an opinion about the condition of my flywheel? I hope it can be reused

http://forums.pelicanparts.com/uploa...1374884343.jpg
http://forums.pelicanparts.com/uploa...1374884360.jpg
http://forums.pelicanparts.com/uploa...1374884380.jpg
http://forums.pelicanparts.com/uploa...1374884396.jpg
http://forums.pelicanparts.com/uploa...1374884421.jpg
http://forums.pelicanparts.com/uploa...1374884439.jpg

Here is a picture of the flywheel all cleaned up after a bath in Simple Green
http://forums.pelicanparts.com/uploa...1374884553.jpg

Here are a few more pictures of the clutch disc to show how worn it was. I wonder how long this thing was in there? Maybe it is the original clutch?

http://forums.pelicanparts.com/uploa...1374884624.jpg
http://forums.pelicanparts.com/uploa...1374884646.jpg


It looks like my flywheel seal was not leaking like I previously thought. It appears that all of the black gunk on the engine and in the transmission housing was from the ripped CV boot. I have a new flywheel seal and plan on installing it tomorrow just to be sure. I am certainly not planning on doing this again any time soon.

http://forums.pelicanparts.com/uploa...1374884801.jpg

Shift fork and old throwout bearing removed



http://forums.pelicanparts.com/uploa...1374885269.jpg


Old pivot bushing removed from the shift fork

http://forums.pelicanparts.com/uploa...1374885297.jpg

New pivot bushing installed

http://forums.pelicanparts.com/uploa...1374885332.jpg

I was not sure what grease to use for the throwout bearing. Since I had some Swepco 101 Moly grease I decided to use it. If that is not correct please let me know so I can change it before I button everything back together.

http://forums.pelicanparts.com/uploa...1374885423.jpg

Shift fork, throwout bearing, throwout bearing guides and shift fork keeper installed :) I must say it is really cool seeing how all of this works. Once I had all of this installed I noticed that the shift fork moves a lot smoother than before. I am sure my throwout bearing was bad as it squealed and the pivot bushing was worn out and there was a lot of play in the fork.
http://forums.pelicanparts.com/uploa...1374885493.jpg

Next up I attacked the leaking shift shaft seal on the transmission. I did not get far and all I was able to do was unbolt the nose cone of the transmission. Once I had it unbolted I gently pried on it and got it about 1 cm away from the main housing but was afraid of damaging it. Do I need to remove the pin from the shaft in the following picture to get the nose cone off? Do I simply need to apply more force and knock it free? Could someone with knowledge of the procedure chime in on how to properly remove the nose cone? SOS, can someone help me!!

http://forums.pelicanparts.com/uploa...1374885811.jpg


Here is a picture of the leaking shift shaft

http://forums.pelicanparts.com/uploa...1374885856.jpg

Since I was not making any progress with the transmission I decided to start cleaning the engine around the flywheel seal. I did not get far there either as I ran out of brake cleaner and Simple Green was not removing any of the old CV grease. Tomorrow is another day (with a trip to Autozone for brake cleaner) and hopefully I will be able to make some more progress. The final pic of the day shows how feeble Simple Green is compared to CV grease.


http://forums.pelicanparts.com/uploa...1374886111.jpg

uh... the cell phone is to call 911 in case something heavy goes onto something soft

glad to see you working on the mechanicals!

they can grind the flywheel but make sure it will meet the spec. when they are done - a moderately lightened new flywheel could add fun, so don't be too upset if you need a new one

I use Bosch red grease (high temp. ign. system stuff) in there - just check the drip point on the Swepco to be sure it is good

also, once you clean up the Mg trans., you ought to coat it with Tectyl or something similar for protection - esp. since FL can get salt spray in most places

Hi Kristoph,
We are getting a deluge tonight. River around Santo Domingo will probably go to a few thousand cfs this evening.

You don't have to take out that pin to get the nose cone off (or for any other reason I can think of). Just the perimeter nuts. Make sure you didn't overlook any. There are locating pins at the top and bottom that are a semi-tight press fit, so it takes a little hammering to knock the cover loose. It might be nice to have it sitting horizontal, rather than vertical. More likely the reverse idler will stay on its shaft (thats what the pin you mentioned holds in place in the nose cone) instead of falling on the garage floor.

Did you not replace the mainshaft seal? It is possible to do without dismantling the transmission. Just remove the throwout bering guide sleeve and you will see it. The moly grease you have used will be fine. Don't use much. A little is all you need.

I don't think the gunk in your bell housing is from a leaking cv joint. Did you have drips from the bellhousing area when you were driving the car? Even though it looks pretty, quite possible the cranshaft seal is still the culprit. Or it could also be the tranny mainshaft seal.

The flywheel is ugly, but it may clean up fine at the machinists. If it has never been cut before there should be enough meat left. The machinist should cut the mounting face for the pressure plate by the same amount as the main surface. he should record how deep of a cut he made ( just the minimum needed to get a clean face please!). Then you should put a shim of the same thickness under the pivot bolt for the throwout bearing arm. This will maintain the correct geometry for the throwout bearing.

Sure wish I had been able to put you to work on those transmissions while you were here. I've got all the parts sorted out (finally!) and two of them back together. The third can stay apart until I need it someday, or the next time you are here

Nice haircut by the way!

DG

I made some great progress today and was able to button up the transmission, which included the shift shaft seal and the main shaft seal. I was also able to clean up some more of the engine and replace the flywheel seal. I was also able to finish one CV axle. Currently my wife and I are going to a Peruvian restaurant where I am planning on eating something exciting like a guinea pig or an alpaca so I will post pictures after dinner ;)

Edit: The restaurant did not have guinea pig or alpaca - what sadness!!

Thanks Randy. It would be pretty funny to call 911 while working on a 911;) So far I have not had the need..... knock on wood (head):) I hope that the flywheel can be machined and I will post more on the results from the machine shop next week. I really hope that I don't have to get a new flywheel due to the cost involved. I checked and the Swepco will be fine.

Thanks Obi Wan for all of your great advice. I would not be on this awesome journey if you had not gently nudged me down the "Rat hole"! I wish I could have been there to help you with the transmissions as well. Maybe I can help you on the last one next summer.

Here are pictures of my progress today.

First I removed the main shaft seal on the transmission and replaced it with a new one. Removing the main shaft seal was a pain and I ended up using my butane torch to melt the plastic seal so it could easily slide out. I ended up cleaning the main shaft and the sealing surfaces with a fine thin brush.

The plastic upper part came off easy enough but trying to pry out the metal portion was difficult

http://forums.pelicanparts.com/uploa...1374973730.jpg

Time for the torch

http://forums.pelicanparts.com/uploa...1374973790.jpg

After heat it easily came out

http://forums.pelicanparts.com/uploa...1374973823.jpg

Here are the new and old main shaft seals

http://forums.pelicanparts.com/uploa...1374973875.jpg

Cleaning before putting in the new seal


http://forums.pelicanparts.com/uploa...1374973929.jpg

New main shaft seal installed :D

http://forums.pelicanparts.com/uploa...1374973964.jpg

I was also able to clean up the engine near the flywheel and remove the old flywheel seal.

http://forums.pelicanparts.com/uploa...1374974107.jpg

New flywheel seal installed :Dhttp://forums.pelicanparts.com/uploa...1374974133.jpg

I finished up the transmission by removing the nose cone, replacing the shift shaft seal, replacing the nose cone gasket, putting it all back together and filling it up with my 2% Swepco gear oil. The old shift shaft seal was a pain to remove but eventually I got the better of it.

Nose cone removed. All it took was a little persuasion with a drift and a hammer

http://forums.pelicanparts.com/uploa...1374981601.jpg

http://forums.pelicanparts.com/uploa...1374981628.jpg


Old leaky seal removed

http://forums.pelicanparts.com/uploa...1374981655.jpg

New seal installed

http://forums.pelicanparts.com/uploa...1374981683.jpg

Scraping away the old gasket material

http://forums.pelicanparts.com/uploa...1374981716.jpg

New gasket before reassembly took place


http://forums.pelicanparts.com/uploa...1374981762.jpg


To end the day I cleaned up one of the CV axles by putting on new boots and repacking the bearings with Swepco 101 Moly grease.


http://forums.pelicanparts.com/uploa...1374981873.jpg


http://forums.pelicanparts.com/uploa...1374981891.jpg

Today I was able to make some more progress towards getting the Rat back on the road. I finished the second CV axle, removed, cleaned, and painted the oil tank, got the flywheel machined and installed the flywheel, clutch disc and pressure plate.:) On top of all that I got to weld patches into the Yellow Submarine at Peter's house!

Oil tank right after removal. Man what an oily mess. When I reassemble I will be replacing all of the seals in the hope that things won't leak.


http://forums.pelicanparts.com/uploa...1375141326.jpg

Oil lines and oil filter housing after removal

http://forums.pelicanparts.com/uploa...1375141362.jpg

Oil filter housing after some serious cleaning

http://forums.pelicanparts.com/uploa...1375141396.jpg

Cleaned up oil tank

http://forums.pelicanparts.com/uploa...1375141422.jpg

Oil tank with a fresh coat of paint

http://forums.pelicanparts.com/uploa...1375141457.jpg

The machine shop I took the flywheel to allowed me to watch and take pictures!!

Pounding out the pilot bearing and the three alignment pins

http://forums.pelicanparts.com/uploa...1375141567.jpg

Setting up the flywheel on the cutter

http://forums.pelicanparts.com/uploa...1375141630.jpg

$300 diamond bit at work cleaning up the flywheel. Overall he did not have to remove very much, which made me quite happy. It appears that this is the first time this flywheel has been cut. He also cut the pressure plate mounting surface to the exact same amount as the surface of the flywheel so all of the geometry would fit. All of this cost me $65. That certainly beats the price of a new flywheel!!

http://forums.pelicanparts.com/uploa...1375141722.jpg

Finished flywheel:D:D

http://forums.pelicanparts.com/uploa...1375141773.jpg

Flywheel bolted into place with the flywheel lock installed to torque the bolts. I torqued them to 110 ft lbs as suggested in Wayne's 101 book. I also made sure to put some grease on the pilot bearing.

http://forums.pelicanparts.com/uploa...1375141863.jpg

Clutch disc and alignment tool in place

http://forums.pelicanparts.com/uploa...1375141903.jpg

Pressure plate bolted down (torqued to 30 ft lbs) and ready to mate up with the transmission

http://forums.pelicanparts.com/uploa...1375142000.jpg