This customer came to our shop with this '01 911 after buying it used and wanted to get everything checked out. The big mystery of buying a used car with an unknown service history is just that, a mystery. Never knowing if the previous owner was on top of the maintance or not can be nerve wrecking but we are here to help.



Parts Installed:
Sachs Motorsport Clutch Kit
AASCO Aluminum Flywheel
Rear Main Seal
Intermediate Shaft Bearing
Oil/Air Separator
Fresh Oil and Filter



To start things out on this 911 the customer noticed oil coming from between the engine and transmission. Not knowing if this was coming from the rear main seal or from the intermediate shaft bearing it was time to get it in and pull it apart. With the bad record of engine failures due to failed intermediate shaft bearings it was not a "wait and see" kind of issue.

Starting to pull in apart.


These kind of findings worried our new car owner a little more, part of the engine casing broken off.


Transmission out and the clutch in the car looks fairly new. We did noticed that many of the bolts were significantly over-tightened which hinted that the transmission had been out at some point.


A look at the oil/air separator that will be replaced.


Flywheel and clutch out of the way and now we can see the rear main leak and since we were this deep already it the intermediate shaft bearing would be replaced as well. There were no normal signs that it was failing but it with everything pulled apart it was better to stay ahead of any issues and just change it out.




Bearing removed


Old and new bearing.


New Bearing and Flange


After the bearing and flange was installed it was time for flywheel, clutch and pressure plate.






Next the Transmission was re-installed, the final pieces put together and it was time to test drive the car.

While out on the test drive our tech also noticed that the window wasn't acting correctly. It would not roll all the way down and also it would at times not drop to clear the window seal when opening and closing the door.

After pulling the panels it was found that the drivers regulator was not adjusted properly so the window could not open fully.

The top of the two screws was the stopper that the window was set to, but the stopper was removed and the window re-learned.






The window issue with not dropping to clear the seal was also figured out and traced back to the lock/latch assembly. On top of that both doors were found to have the same issues and both assemblies were replaced.


In the end this little 911 was back to fine running order and now the customer knew that it was ready for a long life ahead.

Click here for 47 more images of this 911 build process.

 

great pics!

 

nice writeup. Didn't realize you guys got that deep into cars at the store.

 

Nice job, my intermediate shaft went out at 45k miles. Had to buy a new engine. Now im getting a hooting noise thatci think is the air oil separator. Is thisva serious problem? How much do u guys charge to fix?

 

excellent work!