Transmission case separation?

[Timco]

Wait until you put the cover back on the case....

The shift fork rods have to fit into all the roller bearing cups in the cover. The shift forks have to be set just right to get it to slip back together and no rollers can fall out of the main end bearing. I found it near impossible at first then easy enough. I had to use grease to hold the rollers in place on the main bearing.

[Pdwight]

Fascinating thread

[Gelbster]

I applaud your enthusiasm Josh but a few words of caution and encouragement.
You said there was no info on this and lots of secrets. Well here is a lot of info and I hope in return you will agree to add your contribution to the subject ? We need lots of details and photos!
You will need several hours to read through all the links below. Even the Links have Links !
1. You misunderstand which bearings ,which suggests you have not read much on this subject- yet. Look for bearing #16 on the Parts diagram.
Porsche Boxster Parts
2. The short version of the Searching and Reading is that it is usually much cheaper to buy a good used gearbox
3. As these 6 speed 996 & 986 cars age, finding good used gearboxes is going to get more difficult so we shall have to master the repair tasks of 2nd gear + sealed bearings
Suggest you search this forum and others.Whatever you do, please take lots of photos and Post here often.
4. The acknowledged experts in this are GBox and CMS.Get estimates before you proceed - see 2. above.
5. Some of the Posts are deceptively brief and conceal significant problems which are easily resolved if you know the 'secret'. See Timcos helpful comments on Forks/bearings/grease in a prior post in this Thread.
6. Dimensions of the special tool are given in the 2nd link below courtesy of NickHend. If you make one, may I suggest you make several and offer the rest for sale here? Once the CNC machine is set up , producing a few extra is a trivial cost.Then these tools can circulate among the 986 community?Like the IMSB tools.
A few links to get you started:
Transmission repair - Rennlist Discussion Forums
996 Transmission Rebuild and Pinion Bearing Replacement DIY - Rennlist Discussion Forums
Talk to Erik Johnson
Search Kukko 20-20+S -it is a 20 ton slender arm puller required to remove 2nd gear.http://www.samstagsales.com/images/KUKKO_20-S.jpg
For fun here is video that shows the sticky finger test:
https://www.youtube.com/watch?v=8TXPFa4qgTE
https://www.youtube.com/watch?v=PxV4XRTLBKY
https://www.youtube.com/watch?v=VAl9g_Oar7I
https://www.youtube.com/watch?v=PPamCMXcuRA

After all this help for you, I hope that in return, you'll have something to share with us here on the 986 Forum ?

[DarkStar]

Originally Posted by Timco

Wait until you put the cover back on the case....

The shift fork rods have to fit into all the roller bearing cups in the cover. The shift forks have to be set just right to get it to slip back together and no rollers can fall out of the main end bearing. I found it near impossible at first then easy enough. I had to use grease to hold the rollers in place on the main bearing.

Easy... Use a string to hold 1st and 2nd gear rod towards outside of case. Wiggle and it pops back into place.

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