howdees all....
just got done with the fix - total time 6 hrs
2+ hours trying to get the damn fan clutch bolts off

3+ hours for the rest
all in all


job (if you thoroughly read this thread - page 6-7 have some great tips and watch the texasknowhow video)
1. those fan clutch bolts were basically "welded" on - my 12 pt. ratchet shredded them - vice grips - shredded them more -
in the end - found an old wood chisel (yes chisel) and tapped away - biting in to them - till finally they began to spin off -
utterly fricking brutal - save your self the 2+ hours - if the bolts on the fan clutch dont come off with ease - just chisel them off and replace...
2. bump start = piece-o-cake - used a 24" 3/4 Breaker bar - with a 36" cheater pipe - lashed with bungy cords and shop towles for cushion.
pulled the dist. harness plug - turned the key and "bump" the 30 mm crank nut was hand loose - no problemo
3. hand some trouble pulling out the pulley / balancer - A. it is heavy a fux. B. was worried about the key falling out. used a small pry bar to
gently wiggle it forward - once it moved ~ 1/4" inch - then muscle up and spin the pulley till you can feel the key / index pointing to
12'o oclock - then you can take it off complelely - again be aware it is heavy....
4. the 7 dreaded cover bolts....used the cleaning and #3 phillips - head tapping method ($.69 at Harbour Freight)
then used by 12v. bosch mini-impact socket - easy as pie

- all 7 came out pristine and with no problem at all - each on the first try.
no heat needed - no cam out issues - i ended up replacing them with the phh torx kit - but the oem screws came out so clean and unmarred - i could have easily used them again.
5. crank shaft gasket- came out using a screwdrive / mini-pry bar - went back in new with the 2" pvc coupler - someone might want to try a PVC 2" cap unit wherein the back end is closed - was kind of tough evenly seating the gasket - as you are basically using a small hammer to tap a all over PVC pipe and trying to seat the gasket evenly .
6. the oil pump gasket - getting this bugger to stay in place was a bit tricky (but hey i didnt have any issues with the 7 screws)
in the end - using a little permatex ultra grey (did not use FIPG) - held it properly in place - and simply used some more permatex on the
oil pump cover itself (after a cleaning and 1500 grit sand down).
7. re-torque the crank bolt - i used the "14 mm impact socket on the torque converter" method - a second person would have been nice -
as you have to spin the crank - put the bolt on via the trans inspection window - then spin the crank till the socket is both firm on the bolt and against the bell housing wall (mine fell off - thus the need for a second person) - 300lbs is a lot of torque


i set my toque wrench to ~275 lb (the 3/4" from Harbor Freight) + my 36" cheater bar - i got a "click" - i then switched to my breaker+cheater
(to get some more length) and got the bolt to move 5 degrees more....not sure how important 300 lbs is - but am satisfied enough - as putting that much pressure on the torque converter bolts cant be a good thing either....will definitely double check the crank bolt to make sure it is not loose this week.
anyways - again for me things went very smoothly - with little hitch ups and LC is running great and as of now - no more slow leaks....
thanks all for the great tips and advice - and if you are in the SJ bay area and need some help tackling this - just drop me a line...
Bf
209k and rolling....