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Old 12-04-2011, 01:38 PM   #1
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DIY Transmission Rebuild?

I have the typical 2nd gear synchro issue on my 2000 Boxster S. When I bought it, I (regrettably) did not do a PII and overpaid too. Yes, I can analyze the things I SHOULD have done, but I am trying to look forward on how to get us much enjoyment out of my purchase.

I have already done some work on it myself (water pump, radiator, short circuit repair, transmission fluid, oil and filter) which chewed further into the $$$.

The only nagging issue that I am now aware of is this 2nd gear grinding. I have figured out that I can double-clutch (up) into 2nd without the grind. However, that doesn't make for sporty shifting (at least not how I double-clutch) and also doesn't work well for shifting down for a turn.

Is it possible to do a DIY repair on the 2nd gear synchro? Are there step-by-step details available on how to do it? I have seen instructions for other transmissions (below), but not for the Boxster 6-speed. Any help?

How-To: Porsche 915 Transmission Repair Tutorial Part 3 - Porsche Wiki

http://www.thesaabsite.com/9000/9000transrepair.htm

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Old 12-04-2011, 04:01 PM   #2
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http://www.californiamotorsports.net/CMS_shift_arrester%20instructions.pdf
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Old 12-04-2011, 07:34 PM   #3
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Yeah, the G86/20 is NOT a DIY gearbox.
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Old 12-05-2011, 06:04 AM   #4
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A good used gearbox for your car can be found at most Porsche dismantlers. I found one for $1200 shipped and it included a serviceable dual mass flywheel as well. It had less than 60K miles and works perfectly. Compared to a $4K trans rebuild and $800 for a new fw it was a no-brainer.
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Old 12-05-2011, 07:29 AM   #5
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Good point. Where can I find a list of Porsche dismantlers?

There aren't any that I know of here in Charlotte.
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Old 12-05-2011, 04:39 PM   #6
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Quote:
Originally Posted by crumbum View Post
Good point. Where can I find a list of Porsche dismantlers?

There aren't any that I know of here in Charlotte.
Weissach.net - Porsche Parts Suppliers

Lots of them but I found my trans at Oklahoma Foreign.
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Old 12-05-2011, 04:59 PM   #7
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I think I found one from a car that rolled over. Any concerns?
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Old 12-05-2011, 05:01 PM   #8
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... the typical 2nd gear synchro issue ...

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