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intermediate shaft cover

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OK guys, I'm deep into the RMS removal and replacement (R&R). The seal has been fairly straightforward w/ no issues - you can see it installed in the pic. After I get this finished, I'll post a more complete story and pic history. However, for now I have a more pressing issue/problem.

The Bentley svc manual only recommends R&R of the 3 bolts on the intermediate shaft cover. But my internet research clearly shows that the recommended preventative measure is to replace the original cover a newer version which has an updated seal design. Upon this recommendation, I pulled the cover. Here's where the problem began - w/ the cover removed, the shaft had nothing to keep it centered in the opening. I am completely surprised, given all the wonderful engineering of the Boxster, that Porsche has done such a poor job of supporting the tail-end of both the crankshaft and the intermediate shaft and thus creating these leak issues. Oh well.... Anyway, the shaft shifted off-center in the opening, apparently under the chain tensioner's loads (see attached pic). Without the shaft being centered in the opening, there is no way to re-install the cover. I've loosened the chain tensioners, which offer no help. The Bentley svc manual doesn't address this issue and I can't find any info on the internet. Can any of you offer experience/insite? Thx.


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Why did you post this again?

I answered your first post.

Sorry Loren. I'm pretty new to this forum site and after posting the first time, I couldn't find it in the list of "new" posts. Thinking it got buried in the archives, I made a new post under a title that actually addresses the issue.

You're reply is much appreciated and helpful - looks like a tool that I can fabricate without much problem and be back on the road in short order. Thanks again.

BTW, for those of you needing the full info around the RMS and shaft along w/ Loren's answer:


Edited by rodsnhawgs
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