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Old 06-04-2010, 01:30 PM   #1
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Transmission Replacement - DIY or Shop?

So it seems I might be in need of a transmission replacement. The tranny is making a lot of noise in second gear, like rock in a tin can. How hard is it to swap out a tranny? Is this a DIY project for someone with mediocre experience and not afraid to get dirty?

Car in idle:
http://www.youtube.com/watch?v=_QM5vQxZO8w

Car in motion, you can hear at the 12 sec mark, but not very good. At the 30 sec mark you can hear very clear:
http://www.youtube.com/watch?v=YOSvBa-fEus
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14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
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http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
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Old 06-04-2010, 01:38 PM   #2
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It is not that difficult a project, even with the car sitting on jack stands. You are going to need some tools (a way to support the engine while you pull the gear box, a second supporting device or jack to carry the gear box, a good torque wrench, a 10MM triple square socket for one of the tran’s bolts, etc.). Not difficult, but sufficiently involved that you need a good reference manual to guide you through the process if you have not done it before………..
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Old 06-04-2010, 02:06 PM   #3
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Do you know how to change out a clutch? If not, then I'd have someone else do it.
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Old 06-04-2010, 02:18 PM   #4
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No, never done a clutch, but I changed out my suspension...with patience, a Bentley manual, this website, it’s probably possible to do. I have to think about it. I'd guess I'd be looking at about 8hrs worth of work with the proper tools...for my skill level.
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03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
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Old 06-04-2010, 02:41 PM   #5
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Just to give you an idea, I had an old car when I was younger (and poor) that I had to change the transmission on 4-5 times. Bought them from the pick and pull junkyard and kept getting bad ones. Then, when I finally got a good one, it lasted 3 weeks before going out again.

As expected, I got better and better with each switch. For the last one, it still took me approx 2.5 hours to take it off and 3 hours to put the new one on. I'm guessing that it'll take you at least a few days if not more, considering the space you have to work with, my perceived experience from you, and the delicacy that must go into this car. Good luck though. I'll be rooting for you.
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Old 06-04-2010, 05:42 PM   #6
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Quote:
Originally Posted by crios
No, never done a clutch, but I changed out my suspension...with patience, a Bentley manual, this website, it’s probably possible to do. I have to think about it. I'd guess I'd be looking at about 8hrs worth of work with the proper tools...for my skill level.
Crios; someone posted here a complete tranny (and engine removal) with pics and detailed information, if I can find it I'll post it here. Looks like a fun project (seriously) and you will save at least $800 - $1,000 IMHO
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Old 06-04-2010, 06:42 PM   #7
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Quote:
Originally Posted by Gilles
Crios; someone posted here a complete tranny (and engine removal) with pics and detailed information, if I can find it I'll post it here. Looks like a fun project (seriously) and you will save at least $800 - $1,000 IMHO
Crios;

Here is the link for the engine/transmission removal:

http://www.nutrod.com/Nutrod/Home.html

This guy took the time to documents every step for engine removal (and partial disassembling) with great detail however, you won't be going that far...

With the money you'll save, perhaps you may want to consider a new clutch..?
.
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Old 06-04-2010, 07:16 PM   #8
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I went through what you are describing earlier this year. I also did the IMS retrofit while in there along with replacing the clutch and RMS. If you take your time and follow the Bentley Manual it is not too tough of a job. Rebuild through Gbox will run $2400 to $3400 depending on what needs done (for an "S" 6 speed, yours may be less) plus shipping.

http://www.renntech.org/forums/index.php?/topic/32315-ims-rms-tranny-r-r-tips/?
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Old 06-05-2010, 08:40 AM   #9
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Thanks guys for all the help!!! I'm 99% sure I'll be doing it myself so this info is great!
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03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
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Old 06-05-2010, 09:23 AM   #10
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Quote:
Originally Posted by crios
Thanks guys for all the help!!! I'm 99% sure I'll be doing it myself so this info is great!
Cesar, if you were in OC I would offer my help, sounds like a fun project.
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Old 06-05-2010, 01:32 PM   #11
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Due to the notion "you never know what you're going to get," I would strongly consider rebuilding your gearbox than just buying a used one. Not only will you know exactly what you're going to get back, it will likely work better than new. This is also a great time to consider swapping out the factory open diff for some form of limited slip.

As to the difficulty of the swap, it's not too bad. Rear bumper removed, exhaust removed, then pull the gearbox. I'd swap the clutch, replace the RMS seal, and do an IMS upgrade while you're in there, have a good look at your CV joints, then put it all back together and enjoy life for a while
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Old 06-06-2010, 10:42 PM   #12
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I plan on getting it rebuilt. I want to keep my car forever

Spent a couple hours working on it tonight. Jacked it up 2 feet off the ground (all fours), took the rear tires off, braces off, sway bar, and partial exhaust.

Tomorrow, buy some more tools, 10MM Triple square and Transmission Jack adapter, then at night (kids asleep, wife out of town) take off the total exhaust and some more support bars as well as CV Joints.

Tuesday, tranny comes out!

Wed, wife comes home, yikes
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-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg

Last edited by crios; 06-06-2010 at 10:45 PM.
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Old 06-07-2010, 06:17 AM   #13
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Please keep us updated! I'd like to know how it comes out. Also, those guides should be REALLY useful.


Quote:
Originally Posted by crios
I plan on getting it rebuilt. I want to keep my car forever

Spent a couple hours working on it tonight. Jacked it up 2 feet off the ground (all fours), took the rear tires off, braces off, sway bar, and partial exhaust.

Tomorrow, buy some more tools, 10MM Triple square and Transmission Jack adapter, then at night (kids asleep, wife out of town) take off the total exhaust and some more support bars as well as CV Joints.

Tuesday, tranny comes out!

Wed, wife comes home, yikes
__________________
Parts for sale: 4-spoke Steering wheel, air bag, and leather cover ($350 + shipping), Rear zipper storage bin ($100 + shipping), CDR-210 Factory OEM radio, casing, and keys ($100 + shipping), Hand brake handle and hand brake sensor ($50 + shipping), Manual factory leather shift knob ($Free + shipping)
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Old 06-08-2010, 03:46 PM   #14
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Tranny is OUT!!! Gbox here I come!

Total time spent - 7 hours

Difficulty...harder to find a 10MM Triple Square (12 point) socket!! With patience and faith, anything is possible. I would rate this as hard as changing out my brake discs, but a lot longer.
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-Cesar

03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
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Old 06-08-2010, 04:14 PM   #15
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Quote:
Originally Posted by crios
Tranny is OUT!!! Gbox here I come!

Total time spent - 7 hours

Difficulty...harder to find a 10MM Triple Square (12 point) socket!! With patience and faith, anything is possible. I would rate this as hard as changing out my brake discs, but a lot longer.
try a 55 Torx
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Old 06-25-2010, 10:02 PM   #16
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Just an update.....2nd gear was broken in the tranny. I finally got the rebuilt back from GBOX on Wed and reinstalled it. Took me about 6-7 hours.

Tranny Costs:
Mainshaft - $525
2nd Gear - $457
3rd Gear Sync Ring - $90
4rd Gear Sync Ring - $90
Input Shaft Seal - $12
Differential Side Seal - $35
Labor to Repair - $1,200
Shipping - $175

Total = $2,583

Another $600 or so spent on shipping to GBOX, Tranny Oil, tools, Cooler in which to ship Tranny in and misc items.
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03' 986 Midnight Blue Metallic
_____________________________________________
Gemballa Lowering Springs | 18” Carrera Light Wheels | Painted Calipers
14/18 H&R Spacers | Aero Wing & Rockers | Powder Coated Exhaust
Creator of CRIOS exhaust mod | De-Snorkeled | De-Ambered
Light Weight Flywheel | Tinted Windows and Windscreen
Painted Bumperettes | 550 Spyder Grille Kit


http://lh5.ggpht.com/_9sTq_sN1KDw/Si...2009%20055.jpg
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Old 06-26-2010, 09:42 AM   #17
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Quote:
Originally Posted by crios
Just an update.....2nd gear was broken in the tranny. I finally got the rebuilt back from GBOX on Wed and reinstalled it. Took me about 6-7 hours.
Total = $2,583

Another $600 or so spent on shipping to GBOX, Tranny Oil, tools, Cooler in which to ship Tranny in and misc items.
The experience of doing it yourself: Priceless...
.

Last edited by Gilles; 04-01-2011 at 11:03 AM.
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Old 04-01-2011, 08:06 AM   #18
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anyone know how high the car has to be for the transmission to clear?

My jack stands can reach around 17 inches. is that high enough or do I need new jack stands?
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Old 03-24-2014, 01:40 PM   #19
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I'm looking at doing a tranny and/or gear box rebuild, and would happily offer free assistance to one of you guys in So Cal who may be thinking along the same lines.
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Old 01-24-2015, 05:56 AM   #20
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Team,

I have a 2004 Boxster and am in process of removing the 5spd TX. Have removed everything as per the articles and am using the compressor (120 psi) and airtool but none of the bolts are budging. Is it normal, are they supposed to be that tight? Have applied PB Blaster over the late few days but to no avail. If I can't have B budging, I am wondering how I am going to remove D with the added loss of the socket extension?

Is it always that one has to use a long length ratchet or something and undo the bolts? The torque spec is not that high.

Any suggestion, comments will be helpful and appreciated.
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