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Pelican Technical Article:

Porsche Boxster / 996 Engine Teardown & Disassembly
Page 7

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Difficulty Level: 4
Difficulty scale: Adding air to your tires is level one
Rebuilding a Porsche Motor is level ten

  This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster.  The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads.   With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details. 
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Figure 1
Almost got the bearing out...
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Figure 2
It's out!  You can see the circlip around the outside of the bearing.
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Figure 3
Here's the view down the end of the intermediate shaft.
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Figure 4
Use a magnetic pickup tool to fish the bolt out of the center of the shaft.
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Figure 5
Another view of the shaft sans the bolt.
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Figure 6
Here's the infamous bearing on the bench, still attached to our bearing puller tool.
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Figure 7
Here's that tricky circlip that holds the bearing in place.
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Figure 8
Another shot of the bearing.
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Figure 9
Here you can see the intermediate shaft floating around and you can also see the groove that the circlip rides in.
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Figure 10
So, with the old bearing out, we're now going to install the new upgrade bearing available from LN Engineering.  This new bearing assembly contains a special exotic ceramic-coated ball bearing integrated with a specially designed, beefy intermediate shaft cover.  At the time that this is being written, Pelican Parts is working with Softronic to develop a much less expensive kit that uses parts very similar to the OEM ones.
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Figure 11
Here's the bearing installed with the cover removed.  I actually removed a bunch of photos from this article because we accidentally installed this prototype bearing using pressure on the inner bearing races, which is an installation error.  There will be a separate tech article very soon on the installation when we install it into a 996 engine that has a loose bearing right now.
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Figure 12
Close-up of the bearing installed.
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Figure 13
Okay, the bearing is fully installed.  Now we need to remove the cover in order to install the circlip.  Note, that this was an experimental upgrade bearing, so this one wasn't completely 100% operational.  The upgrade we were using here was for the single-row bearing - Charles Navarro at LN Engineering is in the process of designing a universal fit one as I write this article (April 2009).  For the OEM-style replacement kit, there will be two different sized bearings available.
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Figure 14
I couldn't resist taking this photo.  Those guys at Callas Rennsport really mean business.  I mean, look at the size of this tube of Loctite.  Up to this point, I'd only seen the puny 1 oz tubes.
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