refreshing an old horse

I’ve finally started the process of replacing/refreshing many essential parts in the Miata, and I found some nice little surprises!

I started by disconnecting everything from the engine and transmission. Once that was finished I hoisted the pair out of the car to get a better look at things. As you can see I had to remove the front bumper because the engine hoist that I had was pressing against it. I needed the extra clearance.

This is the second time I have removed this engine and one thing that I’ll never get tired of complaining about is rust! The amount of bolts on this car that have broken off or been rounded out and had to be re-tapped or just left there is probably close to 15. But the more I work on it, the more character it gains. Luckily none of the bolts are major ones such as sub frame bolts.

On the flip side there was a lot of grease under there. I’m not surprised but I am at the same time. I’ve changed the gaskets and seals on this many times, and I must have made a goof installing the oil pan because there seemed to still be a leak down there. The sub frame had a nice chocolatey layer on it.

Anyone that has oil leaks knows that there is a funny silver lining about them. Whatever it leaks on it preserves! A nice bonus on an old car.

Hoisting the engine

Once the engine was pulled there were a few things I noticed, some of which I was already aware of. My alternator was definitely bad, the bearings were worn out, and when I grabbed the pulley I could rattle it some. Definitely time for a new one.

This engine & transmission has about 365k original miles. Even though the clutch has been replaced once, and all the rubber has gone through an overhaul at some point in the past, the outer casing showed its age. Which makes me happy it’s lasted this long.

One thing I noticed as I scanned over everything us the Camshaft Angle Sensor, the connector on this partially broke off. It still works, would just rather not have that pop off while driving. So time for a new one! I will also need to replace some of the sensors on top of the transmission since one of the wires broke off when I removed it. Not a huge deal.

When I separated the engine from the trans, I found a surprise that took me back to a memory I had back in 2022 on a long road trip to Maine. My clutch was making some horrible squeaking noises when I pressed it and I was worried I would be stranded, but for some reason the squeaking got better and eventually went away completely for some strange reason. Ill take it lol.

I was fine with it for 2 years, but once I removed the trans, I realized why it stopped squeaking, it’s because the bearing basically disintegrated! The bearings were bone dry and barely held in place.

My flywheel and clutch plate also had hot spots all over them. Which I knew about because I tried to resolve this with a resurface at a machine shop. But no matter how gentle I was it came back. This all stemmed from one time I accelerated hard and popped the clutch at about 2500 when the clutch was not warm. I guess this was the undoing of it because ever since then I have a shudder when going from a stop. I’ve never had issues with any clutches in the past so I guess I rolled a bad pair of dice that one time.

Dead Pilot Bearing ( see the bearings laying around and some are missing)

The transmission revealed a bad oil leak. Which wasn’t the rear main, it must have been the pan gasket, which annoyed me because I thought I did this right about 2 years ago, but I guess its time to re-do it!

Dirty transmission ( with rusty input shaft)

The rust covered input shaft was my first clue something was up with the pilot bearing. This will be getting new oil seals & upper and lower shift boots. Those seem to last maybe 5 years if you drive as much as I do ( 15-20k a year).

Well that’s where I stopped today. I have a list of new parts I am going to add to my existing items after I inspected everything today.

These include:

Rear main seal

FM Clutch Happy Meal

New Shift Boots

New CAS

Remanf AC compressor ( I know its a gamble but I ordered the dryer and expansion valve to keep the warranty on the compressor)

Crank and Cam seals

Timing Belt

Drive belts

Its comical to me just how many times I have taken this car apart thinking its going to be the last time lol. Hopefully this time it will be in good shape for a long time!

Next weekend I’ll post another update! When I have time after I have completed all the maintenance items Ill upload some detailed videos.