1 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCH2005 997.1 3.8L S -> 4.0 rebuild
Reported or suspected cause
magnaflux is not needed...but insurance again comes
Suggestion or failed attempt
No successful repair reported for this finding.
0
Identified cause
1
Suspected cause
0
Reported fixes
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that suspect a cause
1
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0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suspected cause · Original poster
11) Undecided but probably will send crank and all parts to shop for professional matching(to confirm my work) and crank balancing/magnaflux (This is not where this motor had a problem..so I suspect magnaflux is not needed...but insurance again comes to mind))
Leading evidence: 'magnaflux is not needed...but insurance again comes' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, the most frequently mentioned possible cause is 'magnaflux is not needed...but insurance again comes' (1 discussions; 0 report identifying it and 1 suggest it). The most frequently discussed action is 'Replace seals and resurfaced them' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
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Suggestion · Original poster
6) heads were inspected at a shop..they stated guides were good...just changing the seals and resurfaced them
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
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0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
These are separate views of the same evidence. Frequency alone does not establish a fix, and these counts must not be added together.
magnaflux is not needed...but insurance again comes
No successful repair reported for this finding.
0
Identified cause
1
Suspected cause
0
Reported fixes
Read evidence and context
Discussions that suspect a cause
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suspected cause · Original poster
11) Undecided but probably will send crank and all parts to shop for professional matching(to confirm my work) and crank balancing/magnaflux (This is not where this motor had a problem..so I suspect magnaflux is not needed...but insurance again comes to mind))
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
1 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Pelican Parts: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261027T035758Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
I am rebuilding a 997.1 3.8L S motor (D-chunk crack cyl 5) into a 4.0. Likely failure was a gel slug behind the water pump (wrong coolant added?)....Oil was chocolate milk mixture. (bought it this way as a project with 100K miles on it); could be gel slug was from coolant added after Dchunk failure and low coolant showed....I will never know.
Cases are coming back next week from LN Eng with nickies and JE pistons. IMS solution also being installed in the rebuild.
This will be built for street...no plan to ever race...so following decisions were made (I am open to hearing advisement if you disagree on any decision or have opinions)
1) stock rods will be reused (new bearings)
2) Using NEW OEM bolts everywhere (connecting rods, head bolts,crankcase carrier bolts etc.....I was advised if not racing..then ARP would not be needed...only really needed for the high RPM abuse of racing)
3) replacing water pump
4) Undecided on LN eng billet timing chain guide ($330) vs stock ($40) since not racing...might do it anyway for "insurance"...since it is deep in the motor)
5) all new chains and guides
6) heads were inspected at a shop..they stated guides were good...just changing the seals and resurfaced them
7) all new oil separators
8) reusing oil/coolant heat exchanger (they seem to be a suspect part from what I read even when bought new they are no always good...so if it aint broke on that one I dont want to take a chance on replacement)
9) Bought wrist pin insertion tool..plan to grind wrist pin hook away (I read this is the flat six approach) on cyl 4-6
10) will weight and match all opposing pistons+rods+rings+bolts+pins+clips for best balancing
11) Undecided but probably will send crank and all parts to shop for professional matching(to confirm my work) and crank balancing/magnaflux (This is not where this motor had a problem..so I suspect magnaflux is not needed...but insurance again comes to mind))
...lots of other smaller decisions made...but above are the bigger ones or not fully decided ones to give folks a flavor of the project
REAL question for why I am writing...I cant for the life of me find specs for 3.8L crankshaft! Info is not in the WSM. Trying to confirm Journals are in spec for standard main bearings or not so I can make my big parts buy for the rebuild.
Below are my measurements:
Crank Main Journals: Average =62.992 +.0432 / -.0292 (Max=63.03518; Min= 62.96279)
Crank Rod Journals: Average = 52.98794 +0.018 / -0.0131 (Max=53.00599; Min=52.974875 if too many sig-figs please disregard. I measured in inches the converted in excel to metric..not sure why I didnt just do metric....I am just not used to metric.
Full Disclosure: I am mech eng...but this is my first engine rebuild..I will take a few deserved lumps on this not so smart choice to make a $20K porsche high performance motor my first build....I deserve that:-); restored various previous cars and done engine swaps...just never did an engine...but I am having loads of fun!
For everyones interest Pic of Gel slug and D-chunk crack are included here Since I havent seen many when I was looking. (I do videos talking to myself for future reference...not pictures...so sorry for quality)
This is a source reference. Confirm exact model applicability in the original material.
