Winter project - Oil leaks and clutch

[maresdesign]

Since my car is a dedicated fair-weather vehicle (speedster) I thought I'd tackle some long over due projects. I've replaced all the seals that can be replaced with the motor in the car, but now time to drop the motor and get to them all. The car is a 71 911E Targa, now speedster, with a leaky tranny and motor.



Too much grime!





The trans unbolted and separated from the motor so I knew then it was swapped from another 911.

[maresdesign]

Leaking tranny seal



Leaking main seal



Worn clutch and fllywheel

[maresdesign]

Drain the tranny


Four cans of carb-cleaner later

[maresdesign]

Leaking pulley seal

Pulled oil cooler - leaking seals.

First shipment of seals. PVC pipe adapter to install the main seal. Also clutch lever and throw out bearing bushing parts and flywheel.

[maresdesign]

New main seal installed. Used Curl-T sealant.

Pulled chain covers to check tensioners and ramps. Tensioners have been modified as to be a "fixed" type. Since there was no rattling sounds or otherwise I buttoned it back up with new seals.

[maresdesign]

New flywheel bolts to install the new flywheel. I recommend using a brand new tool for the bolts and take your time torquing to spec.


I found another leak. This mystery paper gasket was installed along with the rings to seal the oil sender at the back of the motor. Replaced with new sealing rings and torqued to spec.

Also replaced the intermediate shaft cover seal while i had access.

[maresdesign]

New clutch kit! Replaced everything but the lever. Including the main seal behind the lever/throwout bearing assembly. I used the quid tube as the seal installation tool, just tightened it slowly while watching the seal get pushed in. Easy.

[maresdesign]

I thought since the motor was out I'd detail it a bit.

Found a leak at the oil tank filler neck tube. It had cracked and leaked oil vapor everywhere. It was hard to see until the motor was out.

New Filler neck tube/hose

[maresdesign]

Here's a tricky leak to spot. The speedometer drive seals. There is a large oil ring, a sealing washer and mini-main seal (for the lack of a better term) You've got to remove the assembly from the tranny and take it apart to get to the seal. I don't have pics of the process but it was quite a pain to remove the old washer and seal. Don't forget the sealing washer on the bolt that keeps in inside the tranny.




New clutch and pressure plate installed.



and a pic of everything replaced so far

[maresdesign]

Tranny reunited with the motor.


To be continued...

[maresdesign]

Forgot to show this pic. Using the guide throwout bearing guide tube to insert new tranny main seal.

[june82000]

Looks wayyyyy better! Very informative, great pics also - Thanks!

[rusnak]

Hope you used the special high temp grease on the tranny input shaft. That is some important grease!!

[maresdesign]

Originally Posted by rusnak

Hope you used the special high temp grease on the tranny input shaft. That is some important grease!!

The grease was included in the Sachs clutch kit.

[merlinfe]

Thanks for the great pictures!

[steely]

Really! - great job and thanks for the porn!
Kills the winter doldrums.

[Discseven]

Nice job & post MARES!!!!!!

[maresdesign]

Getting excited for Spring...can't wait to get it back on the road. With no more leaks! Here's some more pics:

Early 911 Speedster or is it a Spyder?



Saving up for new tires.