Ed Hughes

Put the sealant on the bottom 1/2 facing up, on your stand. Dry run assy first. You will be on the clock when the sealant is down.

ReinerFink

Sorry - after re-reading that I was not being clear. I am only going to put the sealant on one half -- however I think putting it on the left (aka top) would be easier, but now that Ed and the book both say "bottom half" I'll go that route.

-reiner

Ed Hughes

I simply think it is easier to work with it on that surface, keeping the top free of goop for handling.

ReinerFink

I just finished measuring the gear backlash of the intermediate shaft:



My play was 0.0762mm which is upper middle of spec. Factory manuals list the following:

New dimension: 0.035 - 0.084mm
Wear limit: 0.10mm

I got the legit VW 387 gauge from Baum tools (I think) however, the fit for the dial gauge had to be supplemented with some metal tape to get a snug fit

-reiner

ReinerFink

Any wisdom on when to install the rear main (flywheel) seal? MikeJ did it after the case was put together, Wane's book says to put the seal on the end of the crank before mating the case. I don't own any magik seal install tools other than a 2x4 and a hammer, so perhaps putting it on before would be best?

jhg41977

I used a oak landscape stake when I installed a new seal after purchasing the car. It worked fine, be careful, take your time and check depth along perimeter after each light tap.

I bought the spiffy tool when I rebuilt the engine. Either way worked well.

jhg41977

When sealing the case it is so much easier if you have a helper. One person to align the case halves and one to lower them. It is also easier when you start bolting it together since the through bolts need to be tightened and held.

Mike J

I seem to remember I did it that way because I wanted to put the seal in with the case halves, but is got misaligned and squeezed out when putting the case together - and given the rush to get all those bolts torqued down correctly, I elected to do it later.

I now have the proper tool to install the RMS, so I would do it later. If I did not have the tool, I would make another attempt during. Do not like to hammer on these seals, and the proper tool puts uniform pressure all around the seal.

Cheers,

Mike

jhg41977

Didn't someone find a section of pvc pipe is about the right size?

Ed Hughes

I bought a large PVC coupling, and cut a large section out, formed with heat to the right diameter, and used it as a dolly to tap the seal in to the proper depth.

What Mike says is the hazard of putting it in before mating the halves. You will have enough to do in a fairly short period, without having to fiddle with a seal that may get cocked up.

Ed Hughes

Wise words.

I also too aluminum flat bar and made retainers to hold the timing chain and rods vertical. About $15, and a lot less than the Porsche tools. Used bronze bushings as cylinder retainers, for about $8.

jhg41977

Pvc pipe in 3/4 diameter I think, also works well for cylinder retainers.

ReinerFink

What is the proper depth? Consulted the 993 manuals but no mention of this job (which really means its the same as a 964 or earlier repair).

-reiner

Ed Hughes

The Porsche WSM does list a depth. Seems it was 2mm, but I'd not swear to it.

jhg41977

2mm