[JFP in PA]

Originally Posted by Jay Laifman

This really is a pain without the correct tool. Here is one of the better threads out there with options: Installing RMS without Porsche Special Tool 9609 + 9606/1 - Page 3 - 996 Series (Carrera, Carrera 4, Carrera 4S, Targa) - RennTech.org Forums

I will say that Porsche would have solved this stupid problem with any of two "easy" fixes:
(1) Put a dang lip inside the case so that the RMS would bottom out on it.
(2) Make the RMS longer/deeper and put a lip on the top outward edge of RMS, like the brim of a top hat, that would hit the edges of the case, which would stop the RMS from going in too far and hold it in the right spot.

I realize that it's too late for #1. #2 might work, but the edge of the engine there is not well machined. So it may not be even enough to get an accurate stopping point.

One more option - put a loop or posts on the face of the RMS so you could PULL the dang thing back out to get it in exactly the right spot. They wouldn't interfere with the moving parts. I'm sort of toying with doing it myself with parts that I could either remove, or which would cause no issue whatsoever if they happened to fall off (like epoxying on a few threads that I could snip off once installed - but they may just pull through any epoxy if I really needed to use them).

I've also thought about drilling through to have a more sturdy riveted on alloy loop to pull up. I think the risk is low that it could falling apart, or even if it did, doing any damage. And I think it could be done to still seal well around the rivet. But, unless someone else has some idea to make it more foolproof, I could never take that risk - and would think it quite stupid (without a better idea).

There are multiple ways to do this, and they have all been written up. It can be as simple as using a $4 plastic pipe coupler and your old flywheel bolts, you could also check around for one of the machined Delrin tools that were made up as the result of that thread (they do an excellent job of installing the seal), or try and find someone with the real factory tool (about $600 at retail, but a true work of art). Most people just fabricate something and take their time to get the seal in straight and to the correct depth; it is just not that hard to do.