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Old 10-04-2012, 06:23 PM   #1
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Transmission Rebuild?

Okay here we go!!

To make a long story short, my previous owner failed to inform me that my 2nd gear synchro is failing. Here we are 6 months later, just becoming more and more frustrated that I look like that guy that can't drive his sports car... It MUST be the transmission

Haha well here we go.

Its a 2002 Boxster S... I work at a German Auto Shop so I can get parts for it without fail. After contemplating rebuilding it myself I decided I should start by pricing out parts. With all parts including all seals, bearings, 1st-6th & Reverse syncrhos, and 2nd gear. It came to a grand total of just over $2,500...

Calling around to "local" porsche wrecking yards (in SF area), Parts Heaven as an example, they all seem to sell used transmissions for $3500-$4500. Of course with a limited warranty.

Calling the dealer they want $8000 for a factory rebuild (Which i get 20% off for wholesale); Which is definitely NOT and option lol

So here we come to my questions!

1. Are there special tools required, like there is in 911 transmission rebuilds?

2. Could I get away with just replacing 2nd gear and it's synchros, plus of course all seals? (Of course I would also visually inspect everything and replace the obviously worn parts.)

3. Are there any guides that I just can't seem to find? It seems pelican parts doesn't have one, my Bentley book doesn't have one, and even searching forums I cant seem to find one. Any help?

4. Has anyone done this before? Tips/ tricks?

All help is greatly appriciated

Thanks guys!
~Brad

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Old 10-04-2012, 06:36 PM   #2
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a little cheaper ...

California Motorsports - Porsche transaxles, gears, differentials, parts and service

or these guys ...

REBUILT BOXSTER GEARBOXES-GBOX Transmission
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Old 10-04-2012, 06:42 PM   #3
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How about $400? No, seriously...

986 five-speed tranny - unmodified Audi 012?

There. Saved you at least a thousand.


I was once looking around a junk yard after I had done a clutch job. I was among the transmission section helping a friend look for a transmission for a Mitsubishi Eclipse and noticed how similar a transmission on the shelf looked like to mine. As a matter of fact, it was the same, and it was labelled under the Volkswagen shelf.

If you actually take a look at your transmission on the Porsche you will see the volkswagen/audi logos on there!

Last edited by Kenny Boxster; 10-04-2012 at 06:48 PM.
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Old 10-04-2012, 06:58 PM   #4
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Originally Posted by Kenny Boxster View Post
How about $400? No, seriously...

986 five-speed tranny - unmodified Audi 012?

There. Saved you at least a thousand.


I was once looking around a junk yard after I had done a clutch job. I was among the transmission section helping a friend look for a transmission for a Mitsubishi Eclipse and noticed how similar a transmission on the shelf looked like to mine. As a matter of fact, it was the same, and it was labelled under the Volkswagen shelf.

If you actually take a look at your transmission on the Porsche you will see the volkswagen/audi logos on there!
Woah, woah, woah. You're joking me. Is this for real? However; I need a 6-speed, not a 5-speed

They talk about 2nd/3rd gear being geared differently. Any idea on the difference? lol
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Old 10-04-2012, 07:16 PM   #5
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I'm serious as a heart attack. However I don't know much about the 6- speeds. The only difference the gearing ration would be 1-2mpg more on highway speeds due to lower rpms at higher speeds.

Lower gearing = more rpm at higher speeds. Higher gearing = lower rpm at higher speeds. Lower gearing is more optimal in racing applications as the torque curve is optimal at higher rpms of 4-5k rpms. Higher gearing is more optimal in econoboxes, as lower rpms= less power but more efficiency. That is why my honda fit is 2,000 rpm going 70mph and that is why the boxster is 2,700 rpm at 70mph, both being in 5th gear respectively.
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Old 10-04-2012, 07:27 PM   #6
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Here is a great write up I've downloaded from one of the forums.

https://www.dropbox.com/s/0yie0ew0cb774fe/2002BoxsterSTransmissionRebuildDecember2011Revisio n3.pdf
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Old 10-04-2012, 07:57 PM   #7
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I have a good used 6 sped Boxstser S tranny for 2,500.00
Its currently in our test car that we'ves used to develop the IMS Solution and now that we are done with that development we don't need to tranny or the rest of the car, so its time to part it out. 48K miles, no issues at all.
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Old 10-04-2012, 09:19 PM   #8
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Why rebuild? A bad synchro is no big deal, just learn to drive with it. The tranny will last 100k miles or more with a bad synchro.

If it grinds on a downshift, just learn to double clutch. I can do a money shift on a tranny with a dead synchro if I want to, not that I would. Any one who has had an Italian car can vouch for this.

If it grinds on an upshift, try this. When you go shift from 1 to 2, right before you shift, with your foot off the clutch, pull down gently on the shifter towards 2, not too much pressure, keeping the light pressure on the shiftert, push the clutch in and it should go right in.
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Old 10-04-2012, 11:51 PM   #9
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I went through your exact scenario 2 1/2 years back, it was a 2002 S also. Looked into rebuilding it locally without luck, ended up sending it out to G-Box for rebuild / 2nd gear syncro. It ran a touch under $3k with shipping both ways, they did a great job. I also addressed the IMS while in there, put in a new clutch too.

Last edited by coreseller; 10-13-2012 at 02:08 AM.
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Old 10-05-2012, 03:30 AM   #10
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Thanks! Now I know what the beautiful 50+ year old puller with two sets of extension arms I have from my dad was used for. As you would expect, my old unit makes the one in these photos look like junk.

PS I disagree with San Rensho, not addressing the synchros is like allowing a cavity to progress into a root canal.

Last edited by Ghostrider 310; 10-05-2012 at 03:32 AM.
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Old 10-05-2012, 05:25 AM   #11
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Wow, so much for getting a S... I'll go a-wall if I get IMS AND a tranny rebuild.
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Old 10-05-2012, 08:24 AM   #12
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Originally Posted by Ghostrider 310 View Post
Thanks! Now I know what the beautiful 50+ year old puller with two sets of extension arms I have from my dad was used for. As you would expect, my old unit makes the one in these photos look like junk.

PS I disagree with San Rensho, not addressing the synchros is like allowing a cavity to progress into a root canal.
If the gears aren't grinding, I would thing a bad synchro in and of itself is not going to cause any problems.
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Old 10-05-2012, 11:21 AM   #13
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If the gears aren't grinding, I would thing a bad synchro in and of itself is not going to cause any problems.
If the gears weren't grinding there would be no problem at all, I agree. But they are. And when it's cold its nearly impossible to get it into gear. I have no idea how long the previous owner may have drove around like this, and second gear is probably starting to round off..

I must say, Jake you're a life saver, I'll be in contact with you shortly. Thanks a ton
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Old 10-05-2012, 12:23 PM   #14
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Borrowing this topic a bit, is it actually possible just buying a Audi 012 gearbox and install and there will be no difference in the feel?

I have problems with grinding sometimes and found a Audi 012 with 25000km on it for like, 300 usd, will do my clutch and ims next spring and if this is the case, i will drop a new gearbox in there also.

Have a 5 speed manual, 2.5l engine from 1998

Last edited by tobiasr; 10-05-2012 at 12:29 PM.
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Old 10-05-2012, 12:54 PM   #15
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Okay here we go!!

With all parts including all seals, bearings, 1st-6th & Reverse syncrhos, and 2nd gear. It came to a grand total of just over $2,500...
If rebuilding the trans as a DIY project is within the scope of your capabilities, I think you are going overboard with your parts list.
All you should need is the 2nd gear synchro and a seal kit. If you are worried about damage caused by a long period of shifting while grinding, you can replace the 2nd gear dog teeth and possibly the 1st/2nd gear slider. That should be it. Why would you even touch or replace any other parts?

Of course, once you get in there, you may find that the trans is worn out extensively, at which point you should consider buying a used trans. One of my track buddies broke his 5 speed trans on his 99 Boxster. He was able to find a used trans for $700. Be patient and a good deal on a 6 speed trans will come along. A lot of Boxsters get parted out due to dead engines.
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Old 10-05-2012, 08:03 PM   #16
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I found a 5spd for $750 and a serviceable stock Dual Mass flywheel for $150 at OK Foreign last year. Even with shipping it was far less than SoCal dismantlers. Go fishing and see what you catch.
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Old 10-06-2012, 08:04 AM   #17
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5-spd replacements are readily available for well under $1,000. The 6-spds seem to be harder to find and quite a bit pricier (~$2,500). You may have to be patient to find a good deal on a 6-spd.
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Old 10-08-2012, 09:27 PM   #18
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As much as I want to be patient, it's hard to be, as i feel like this is going to be needed sooner than later.

Seventythree, you seem to have the same view on this as i do, however all the other guys at the shop i work for seemed to suggest replacing everything else at once "since you're in there"... Meh, seems like a waste of money to me.

But this still doesn't answer my biggest concern; Are there special tools to open/unbuilding the trans?
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Old 10-09-2012, 10:59 AM   #19
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G Box fixed my 2nd gear grind as well 2.5 years ago now all I have to do is warm the car for 90 seconds or so and shifts pretty smooth into second all other gears were and are fine. From what I've read here the 6-speeds grinding into second is a common problem that G Box has figured a fix which Porsche itself has not. Lots of posts on here about G Box. Good luck.
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Old 10-14-2012, 12:23 PM   #20
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Still need a trans . Does anyone have a good source?

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