Seth and I made lots of progress today, which is pretty impressive considering just how small and frickin cold my garage was today. About 40 degrees I'd say. Closer to 32 on the floor. Brrr.... I haven't lived in the midwest for years, my blood has definitely thinned.
So the goal today was to get the exhaust and driveshaft out. We had an exhaust leak at the passenger manifold to pipe connection, and one in the back section of the Ansa piece that we hope to weld up while it's out. We figured out that the leak at the manifold was due to a frozen nut that wasn't clamped down properly. I'll soak it in Evaporust to free it up before reinstalling.
I hate exhaust work. So I was pleasantly surprised when all but one of the exhaust nuts came off, and we had the whole exhaust out in less than an hour.
Pulling the driveshaft also wasn't as bad as expected. Seth seemed to alternate between "why the hell did they design it this way?" (and of course the answer is always "Because Italian") and "this is way easier to work on than a 944.
While I was fighting the 19mm bolts on the driveshaft - the last shop to work on them torqued them to about 1000 lb-ft - Seth took the time to swap the plugs with a new set of Bosch non-platinum plugs to hopefully cure a misfire at idle. We'll need to fix a leaking valve cover gasket, but we can do that when we torque the heads.
Once we had the driveshaft out we could finally see the broken front giubo, and discovered a broken bearing at the front. The bushing at the tailshaft looked ok, but if I can find one cheap we'll replace it.
Next up is pulling the clutch to check it while we have it this apart. The transaxle bushings are supposed to be newer and poly, so that's a bonus.
Does anybody know where we can find the bushings from the front of the driveshaft? Specifically #5 in the photos below.
I believe we are also missing a rubber piece from the rear of the driveshaft.
Also, does this center support look like it needs to be replaced? It seems to have taken a set, and the rubber is cracking, so we plan to replace it while it's out.
Thanks for all the help so far gang, I'm excited to get the driveline vibrations sorted and the clutch properly bled so we can take it for a good drive.