Help - '02 S Manual Transmission Oil Change - 986 Forum - The Community for Porsche Boxster & Cayman Owners

barkinfool · 11-06-2012, 05:53 PM

Frustrating evening & could use some help / advice from the experts. My low mileage '02 S has never had the transmission oil changed, so decided to take that on this evening after reading the Bentley, 101 Projects book & Pelican site. After putting on stands & removing the underside covers (the metal under plate was quite a struggle to remove as never removed before -- force won the day), I was left with clear view of the transmission. Unfortunately, I have been unable to remove what I'm pretty sure is the fill bolt. Adding a bit to the confusion is the fact that the 101 site photo seems to be a mirror image / on the wrong side of the transmission, so there is a lingering doubt in my mind that i'm working on the correct hole.

First, here's my labeled photo. I believe this is correct, and the fill bolt will not come out...

Here's the photo on the Pelican site -- seems to be a mirror image, on wrong side of transmission if I'm looking at this correctly -- I don't see anything like this on my passenger side of the transmission...

So, I've tried PB Blaster penetrating oil, I've applied as much removal force as I can muster with my socket (with the 10 mm hex), and I've even taken a torch to it & can't get it to budge. Suggestions? I'm stuck!

kls · 11-06-2012, 08:07 PM

I just changed the oil in my '04 and the fill plug was on the driver's side. It was not the 17mm plug that the 101 projects indicated. Instead it was the idiotic 16mm triple-square system, which is the same as the drain plug. I don't remember it being very difficult to remove.

derfo · 11-07-2012, 01:45 AM

Hello Barkin
You can try this if you want, it has worked for me many times over the years. You will need a nail punch with a thin end, now if you grind a point on it your ready to start. Douse sump and fill plugs over night with some penetrating oil. Then what you do is, on the flat of the plug near the outer edge punch a good indent, then angle the punch, about 45 degrees, pointing in the way you undo the plug ( anti clockwise normally ), give it a good strike with the hammer, You may need to hit a couple of times, at all time make sure the punch is pressed firmly on the plug. This should do it, watch for slight movement, that's all you need , then get you spanner on it. I always fit new plugs after and put some copper grease on for easy out next time.

j.fro · 11-07-2012, 02:03 AM

Barkinfool
You have identified the fill plug correctly. Yeah, it can be tough to break free. I usually put a 26" pipe on the end of my Allen wrench to get the initial break. Another option is to put an impact wrench on it. Also, get that aluminum brace out of the way.
I think that other trans is in a 911.

barkinfool · 11-07-2012, 04:43 AM

OK, thanks for the suggestions so far. I will give it another go & update you with results.

barkinfool · 11-07-2012, 06:15 AM

Update: Removed the aluminum brace & that made access a lot easier for even better leverage - thanks for that J.fro. I tried with all my might to get it to break free & it just would not do it. I guess i'm now going to have to go acquire some additional tools to get this free. Thanks again for suggestions & if anyone has any others, please post. Thanks.

The Radium King · 11-07-2012, 07:05 AM

101projects shows a 5-speed; you have a 6; different beasts.

mine came out easy, but i am strong like bull.

just in case, don't drain your xmission until you are certain you can get the fill plug out!

Mark_T · 11-07-2012, 03:44 PM

Have you tried a good impact gun with a good impact hex socket?

SeanZ4 · 11-08-2012, 06:02 AM

barkinfool, How many miles on your 02S? Mine is a '00S with only 41k and the original trans fluid and I've been thinking about changing it. Did you use the Porsche brand stuff?

The Radium King · 11-08-2012, 06:37 AM

yeah, y'all must be right on the 911 transmission. i just saw it labelled 5-speed and realised quite quickly that it doesn't look anything like my 6-speed. upon further examination it deosn't look anything like a boxster 5-speed either. there's a few red herrings in 101projects; all those things that look so easy with the test engine out of the car are a different ball of snakes in real life. still an excellent resource, however.

i used redline in mine and am happy. i think it is jfp that is adamant that you use oem. always a good debate when it comes to lubricants.

kls · 11-08-2012, 07:24 AM

I used the Swepco 201 as recommended in the 101 book, but for the first time ever my transmission is notchy until it warms up. Next time it will be OEM.

944boy · 11-08-2012, 11:10 AM

The later 6-speeds are also again a bit different. For one the slave cylinder cannot just be replaced with the transmission attached.

Swepco 201 is good for cars that get tracked but will be notchy. I was given a combination that so far shifts BEAUTIFULLY! Better than the stock fluid at 100K.

barkinfool · 11-11-2012, 04:22 PM

Sorry for the delay in getting back to you, I took a weekend trip & just got back.

Sean, changed it at 28,500 due to it being 11 years old vs symptoms or mileage. Used Porsche trans oil which was > $40 a liter so it is spendy, for 3L ~$130, but amortized over that much time not too big of a deal. Shifts well, not sure there is any difference from before the change, but I have more piece of mind.