Originally Posted by Homeboy981 (Post 342578)

On a 6 Speed… Instructions say to drill a hole and insert a drywall-type screw and then, using prybar/pliers you can extract. I found that part to be true.

The tricky part was putting the transmission seal back in! Make sure you get it in FAR ENOUGH! If you are replacing the Throwout Bearing guide Sleeve, as you should, take the old one, invert it, and insert it FORCEFULLY (up to and including banging it with a mallet HARD). It MUST SEAT very well up against the lip of the transmission housing to seal.

My PO did not seal it well and ruined the clutch/flywheel/Throwout Bearing. There was also a couple pounds of grease mixed with dirt INSIDE the tranny housing…it was a mess!

TEST IT BEFORE YOU INSTALL:
CAREFULLY tip the transmission housing forward so you can test the seal for runs, drips or errors. Also, IF you notice ANY transmission fluid leaking out at time of re-assembly… the seal is NOT SEATED ENOUGH.

Here is a pic of the seal in question.
http://986forum.com/forums/uploads01...1368536440.jpg

Again, this is a Boxster S model, with a 6 speed. The 5 speed has a larger flange and is a larger diameter.

Hope that helps you get it together!

Originally Posted by ccjazz (Post 343206)

I just love watching these DIY's. You are obviously very particular and it shows!

Great work, beautiful Boxster you have there....worth every minute of your efforts.

So, do you plan to investigate the tranny seal further?

Originally Posted by Paul (Post 343210)

Well done! Using the correct tools always produces a better chance of success.

How much oil was in the IMS tube?

Originally Posted by Paul (Post 343282)

FSM says 26 ftlbs for the guide sleeve for the release bearing on transmission housing for a 97-99 Boxster 5 speed.

Originally Posted by Meir (Post 343294)

Very nice Doc.
You really need to elaborate on your cleaning technique.
:cheers:

Originally Posted by woodsman (Post 343380)

your work is inspirational, your method, calming. You make it all seem so easy and worry-free! Thanks again for detailing all of this:D

Originally Posted by HammerESQ (Post 343793)

Great looking project. How long are you budgeting for all of the work? I actually just got done with the same work last weekend.

Overall I did:
* Full 3 piece clutch job
* IMS Bearing, I went with the Pelican kit and will replace again on my next clutch.
* Plugs / Coil packs / Plug tubes
* RMS
* Engine oil change
* Swepco 201 gear oil

I wish I had actually thought of it and replaced the AOS, Coolant Tank, and Oil Tube, I've got 40K on my AOS, and the coolant tank and oil tube are original with 95K on them.

Here are a few pictures: Porsche Transmission Drop - Imgur

Also, if you haven't, change your gear oil now while your transmission is out. It's much easier when you don't have to deal with pumping gear oil in from under the car. I was going to put my transmission on an engine stand, but wound up using a lounge chair that my neighbor was throwing away. It fit perfectly (picture 8).

Originally Posted by drbodzin (Post 343283)

Really tight quarters, especially the top left screw on the themostat.

Originally Posted by AKnowles (Post 344393)

Looking really good. Just curious but are you going to refurbish the supporting members? I figured if I ever removed my engine or transmission that sionce I had to puill all of them anyway I'd take the opportunity to clean them up and repaint them. As I saw in a similar thread.

Just wondering how difficult/easy it might be, so if you do decide to do it please let us know.

Originally Posted by Meir (Post 345259)

hi Dr.
the correct sealant is loctite 5900.
Porsche 986 987 996 Carrera Loctite 5900 Sealant Gasket | eBay