Output Shaft Removal for 2002 Boxster S G86 Transmission
 

I was having the dreaded 2nd gear slip so my friend and I took the transmission out of the car for a closer inspection. We have the transmission out and on a bench and were able to identify the issue. The issue is in fact the synchro and possibly 2nd gear.

Now here is the question. We have been unable to get the tapered bearing out of the top of the output shaft in order to get to 2nd gear. Does anyone know how to get this tapered bearing out? I have attached a photo for your review.

http://986forum.com/forums/uploads01...1324345488.jpg

They are either pressed on are held in place by a snap ring...snap rings should be a certain points to hold assemblies in there right position. Get a diagram be fore you start disassembling it.

2nd Gear Fixed!
 

We figured it out. We had already removed the snap rings and 2 spacers. The gears needed to be pulled out using a kukko gear puller in 2 stages. In stage one, first gear and all components above the gear were removed. In stage two, second gear and all remaining components were removed. A significant amount of force was required to remove the gear puller drive screws via a pneumatic impact wrench set to 110 psi. The estimated torque required to move the bearings along the shaft is calculated at 305 foot pounds which would generate 3660 pounds of force per inch. The resultant force on the ½ inch shaft of the gear pullers is 7,320 pounds or 3.66 tons of force.

We removed the gears and noticed that second gear was damaged. We replaced the gear and syncro and reassembled. We were sure to test the transmission on the bench before we reinstalled it. While the transmission was out we replaced the IMS, Rear Main Seal, Clutch, and CV Boots.

We are working on a complete article detailing our adventure.

In all the job took about 5 days. But my Boxster shifts like butter and has never driven better.

*thumbs up* & awaiting write-up .. not that I'll ever have the balls to attempt this myself .. but love to read about other ppl's exploits .. :cheers:

Congrats and please do take the time to do the write-up. Where did you source the puller?

Gear Puller
 

I got lucky and sourced the puller from an area independant mechanic shop on loan. Because of the space between the gears (see picture in the post below) you have to have a gear puller with thin feet. I used a Kukko gear puller.

http://986forum.com/forums/uploads01...1327548468.jpg

http://986forum.com/forums/attachmen...1&d=1327550235

Update, I have been driving the car for a month and it is absolutely perfect!

Custom Tool
 

Oops, I almost forgot. Because of the hollow shaft in the Boxster S transmission, we had to create a tool to allow the puller to have somewhere to apply the downforce.

http://986forum.com/forums/uploads01...1327548703.jpg

http://986forum.com/forums/uploads01...1327548733.jpg

http://986forum.com/forums/uploads01...1327548830.jpg

I am still working on the article. There is a lot of data so it is taking some time. In the meantime if you have any questions please ask.

Parts Replaced
 

I have had some inquiries about the parts I replaced during the project. Here is the list:

• RMS
• IMS
• CV Boots
• 2nd Gear
• 2nd Gear Syncro
• 2nd Gear Selector Sleeve
• Clutch
• Pressure Plate
• Throwout Bearing
• Brake Switch
• Primed and Painted the Exhaust
• HID Driving Lights (Bonus)

http://986forum.com/forums/uploads01...1327549734.jpg

Fantastic!

Groundzero, please check your private messages.

Very happy to see this I am looking at doing the same on my car. If you don't mind me asking...What was the cost of the transmission parts ?

Parts Cost
 

The transmission parts cost as follows:


Gear 996.302.942.00 $385
Shift Sleeve 996.304.061.02 $450
Syncro Sleeve 996.304.611.00 $130

Article Finally Done
 

Thank you for your patience. Here is the article. Let me know if you have any questions.

Wow!
 

this is awesome. file saved. :cheers:
my 2nd gear is fine (for now) but i'm sure some people want to know how much its going to cost them to ship their transmission to you. :D

Worth the effort
 

lol, that is funny. It was all worth it and it is everytime I put the car in second and accelerate!

YeeHaw!

Congratulations!
 

You've made a significant contribution to the data base!

Thank you
 

I love to help the Boxster community. I have saved a lot of time and money from others articles.

Thanks for the encouraging words.

Does anyone have a copy of the article. Rebuilding 2nd gear on a 996 and need to do the same job. Thanks!

Boxster Transmission Repair Documents
 

Thanks for reaching out. I have 20k miles on the car since the repair and it has NEVER slipped a gear and is still running as smooth as butter.

Here is a Dropbox link to all documents I used as well as an article that my friend and I put together to describe the process.

Boxster Transmission Repair Documents

Let me know if you need anything and happy repairing!

Thanks so much for putting the time and effort into publishing all this info.It was a lot of extra work for the benefit of the 996/Boxster community.As far as I know this is the only such diy guide to this important project.
Would you happen to be selling an old 944 strut part?? I need one and when I am done I'll pass it on to the next Forum member who needs it .I'll also add to your excellent write up.
I am trying the pulling with a Harbor Freight 12 ton puller.It will be interesting to see if it will fit .Certainly a little grinding will be required to fit. Yes, it was a lot cheaper than the German Kuko puller!But only if it works.
Surprised not to see the sealed bearings in your parts purchased list. I think I recall you bought the parts from Eric at Gbox?
Thanks once again for your work.
Mod: That work should be preserved in a special section on this Forum ?

Here is a photo of the jaw/leg of the Harbor Freight 12t puller. If you compare it with the Kukko puller ,you'll see the difficulty of fitting the very large 'claw' in the tiny space around the gear cluster. I suspect that if you grind enough material off the claw to fit,it will weaken the claw to the point where it will break before the gear set can be extracted. Possibly, the fact that it uses 3 legs,not two like the Kukko - may help?
I am wondering if we are using the correct tool to pull the gears and bearings off. A bearing separator would easily fit in the tight space but I have not tried it.Too weak?
Another problem with the HF 12t puller is that it is very heavy/awkward to set up and is dangerously powerful.It could do a lot of damage to that hollow shaft!

Amile,
I am not an expert but:
AFAIK ,the 6 speed transaxle in the Boxster S & the 996 is largely the same internally.It is the Getrag G466.That is the # for the whole transaxle not just the gearbox. The rear of the gearbox case is different because of the different mounting.
Just be careful you don't confuse the 5 speed G86.00 &G86.01 in the base Boxster with the G86.02 6 speed in the S. They are not the same.
The 996/Carrera gearbox is referred to as G96.00 & G96.01
The G96.50 and up are totally different(GT3 etc)
Getrag - Wikipedia, the free encyclopedia
The authority on this subject is Eric at GBOX:
PORSCHE RACING AND STREET GEARBOXES-GBOX Transmission
PORSCHE 986 BOXSTER TRANSAXLE SPECIFICATIONS – California Motorsports Inc
It would be good to have a definitive correction to all these part numbers!

Gear Puller and Misc Ramblings...
 

I am glad that I can maybe fill in some knowledge gaps. I am here to ensure that these marvels of engineering stay on the road and are not given a bad rap because of the mishaps of others. BTW, I believe that 3 cars, besides my own, are back on the road due to this forum and the knowledge it contains.

Now on to business...

While the Harbor Freight puller is quite a bit cheaper than the Kukko, you would probably do yourself a favor by buying one on eBay and then selling it when you are done. I had tried many other pullers before just biting the bullet and finding a Kukko I could use. Make sure to get the one with the slender arms and extension. From what I remember, both are necessary.

As far as the strut assembly, I have one but I don't really want to sell it. Mostly for sentimental reasons. I would be fine with you using it but how would I ensure that I get it back? Nothing personal....for some reason being backed into a corner and figuring out something that seemed impossible has left an indelible mark :)

If anyone knows anyone that can cut thick plexiglass into a circle please let me know. I want to make a coaster out of the old 2nd gear that I removed from my Boxster for my work desk.

Please let me know if there is anyway that I can help.

Happy Motoring!

Great info-thanks
FYI to others the correct(????) Kukko part number is "KK20-1+S" The S = slender arms. The cost seems to be around $300 on EBay.
This is a 2 arm puller. I am still confused about why a 3 arm puller would not be better?

996 Rebuild...
 

Amille,

I would agree with Gelbster, the transmissions are different. However the basic principals of the work done I am sure are very much the same. I would think that the tools and steps necessary are also very similar. The good think about these cars are that they are very mechanical. (At least for the ones built in the early 00's). Please keep us informed on how it goes.

Thanks again for checking our my article.

Go to a plastic store. Most of them can cut as well

I've had good results using a jig saw .The reverse tooth blades seem to work well.
Like this:
http://www.amazon.com/Bosch-T101BR-4-Inch-10-Tooth-Blades/dp/B0000223G0
I found some useful Youtube videos too.

This question if for someone that's opened up a G86.20. How hard is it to separate the bell housing from the rest of the gearbox? I'm considering the feasibility of trying to change the bell housing for an Audi one. When you split the box, if I remove the differential at the same time, can the gearset be removed as a unit or does it need to be stripped down completely?