6 Speed Conversion.
 

I am going to be swapping in a 6 speed. The 3.4 in my car should work well with it. I am going to be pulling my tranny tonight to just get the ball rolling. The new tranny will be here next week and I am sure I am going to have a long list of parts for my dealer. Pics to come. Let me know if you want any specific pics while I'm in there.

P.S. I'm hoping there is no play in my dual row IMS bearing. I want to leave the stocker in. Knock on wood.

Most guys love the 3.4 with a 5 speed. What's driving your decision to go with a 6 speed?

um.. have you actually spoken to someone who has physically done this?

The parts list is very deep to pull this off *without* custom built axles.

I'm going to test you here:

List off the parts needed for the clutch

1.
2.
3.
4.
5.

Second this.

I have done several.

The 987 cars are MUCH easier. The 986? not so much.

I asked the clutch question because I made a huge MISTAKE that cost us a top 10 finish at Daytona. I will never forget *exactly* what clutch parts need to be changed out!!

Don't scare me here. My one question is, why do I need custom built axles?

Parts list.

All S parts.

throw out bearing and tube
Clutch kit
flywheel
I have the updated lever already
slave cylinder
new flywheel bolts
don't care about exhaust hanger stuff - easy enough to fabricate

I was going 6 speed because this is the second 5 speed that I've had that now rattles and moans while rolling in first and second gear. Am I missing something here? Brad you probably have the most knowledge - why do I keep having all these 5 speed tranny issues. Right now i'm on a cayman 5 speed. I dont miss shifts or grind gears and am running royal purple. It works perfect but is just noisy as hell. I may pull it tonight just to re install it if I find something that is rattling or loose.

Any info that i may not be aware of please help me out. I can cancel my tranny order if you give me good reason.

and the part I *needed* to change? required a custom piece to work in the 986 non-s

Does it have the light flywheel in it now?

Solid center stock disc? or spring centered sport disc?

Nope stocker for a 5 speed cayman


What was the one piece?

Solid is in there now with 2 piece flywheel

The BoxsterS axles are completely different from the nonS axles (length/width)

Plus.. the S axles do not pass through the nonS upright correctly.

The S runs a wider wheel bearing than the nonS so the stub axles (that don't come off) are longer for the wider wheel bearing in the S upright.

That is just the *tip* of the iceberg

shift cables and clips are different, transmission mounting brackets are different, and the 6 speed is longer than the 5-speed so your current axles won't work. you can get the longer 6-speed axles, but then I think you need s or 996 wheel carriers as well. or custom axles. good opportunity to upgrade to 996 brakes. I could be wrong of course.

It shouldn't rattle with a stock dual mass flywheel and stock disc.

I **promise** the 6 speed WILL rattle (when warm) with the light flywheel and stock solid center disc (the spring centered disc helps) *some* but not enough to justify it's double the stock price.

So, 5 speed axles won't mount up your saying? I understand all the S axle issues. If the 5 speed axles don't mount up, I have to make a $2k phone call right now :)

Shift cables are MUCH shorter!!

Clutch: The slave cylinder is incorrect.

Change it to the S slave? No problem except Porsche changed the hard line fitting.

Replace the hard line front to rear? or have a new hydraulic line made to go from solid chassis line to soft line to slave.

The 5 speed axles wont work at all.

OK, OK OK OK OK OK.... FML I have to call the place now and cancel. Time to look for a new 5 speed tranny then. I'm guessing. The only plus is there cheap as poop.

Jaay?

The real solution here? CaymanS 6 speed. It's identical in shape/size to the 5 speed.

and.. want to be really sneaky? Find the 987 BoxsterS 6 speed. It has lower ratio's than the CaymanS 6 speed.

Jaay,

I ran a 340hp 3.4 against the 2.7 5 speed with great success. The gear ratio's for the torque made it feel like a true close ratio racing trans!!

Cancelled. HOLY ****************!!!!!!! that was close. I owe you all a beer and dinner and lunch and a stay at my vacations homes. :)

You have the right idea, but the shear number of parts to do it correctly? Is enormous. :barf:

Do like we do and look for a BoxsterS with a popped motor for 5k.

You get:

3rd radiator
GT3 size water lines front to rear
6 speed
Bigger brakes
Bigger wheel bearings
Bigger CV's/Axles

What do you think could possibly be rattling in my tranny at idle, out of gear foot off the clutch. When rolling in 1st and 2nd foot on the clutch there is a whining whiring noise but not if in fifth and rolling. It shifts perfect, the clutch grabs hard and the gear oil I just pulled out look great minus a tiny bit of metal shaving.

Flywheel shot?
Disc Shot?
Throw out bearing?

It has been ratting for over a year now and the rolling noises are now new.

Again thank you soooooooooooooooo. Much for saving my ass on this one.

Little secret?

Run thicker gear lube.

I have several 5 speeds apart right now. The biggest issue we see is the two T60 torx screw back out and need to be checked for torque.

If they come loose, it effect the 3-4 upshift (the most)

well beside the fact we are ripping the teeth off of 3rd gear and wiping out the 3-4 slider.. LOL

If the flywheel goes 1-1 (the face is supposed to rotate X number of degrees) then yes, you will hear the rattling you are describing.

I will update later. it's 4pm here have to get the jerk chicken on the grill. After diner I am going to go over all the external bolts like axle bolts, bell housing, linkages etc. Maybe something is off. I can't see how but it's worth a shot. I'll try thicker fluid. I just put in 75/90 royal purple but I have no problem pulling it out to try something else. Thanks again. I will check back with my findings.

Jason

FYI:

start the car (warm it up) and stick a long screw driver against the CAT on each side. Listen for a rattle.

Theres only one set of cats, high flo fabspeed cats on the car. I doubt there shot, but I'll take a listen. still doesnt change my noises. Clutch in at idle no noise, foot off the clutch at idle rattle. Clutch in or out rolling 1st and second there is noise.

I'll take an ear to it after diner. Thanks again for all the advice and you really just saved me thousands.

It will be the flywheel.. and *if* it is the flywheel.. you need to get it out of the car quickly before it ruins the rear main bearing, then takes out the no. 6 rod bearing :(

Fly wheel is an easy fix. I may drop the tranny for fun. Takes about an hour and than I'll have more answers. It's nice an cool out tonight here so I may just do that.

I know there is a plenty to talk about the aasco fly wheels but any thoughts as I trust your opinion.

I personally stand in front of Randy Aase and discuss the amount of bull_**************** surrounding them.

I have ran them since 2004. I have had engines fail shortly after installing them.

You know why the engine failed? Because the previous dual mass flywheel was bad causing a vibration. When it failed, we went back in with a light one. The engine failed a few 100miles later.

Now, you tell me. Did the alum flywheel cause the issue? No.

If the people who are spewing the sh-it about the light flywheels would open up to speaking with factory trained Porsche techs (Gold Meister badasses) they would learn what the techs see at the dealerships about failed engines with bad flywheels.

I personally experienced an engine failure with a bad dual mass. It was BAD out of the box (I made a HUGE mistake) by not checking it prior to install. Called on 6 different Gold Meister techs to ask them "Do you see bad dual mass flywheels out of the box/new"?? The answer: 2-3 a week and SIX different dealerships. They are lucky, they know to check. I was in a hurry and slammed one together without checking it.

I ate that engine build.. that sh_it sadnwhich did not taste good..

Brad, your awesome. I have a 5 speed on the way 600.00 bux! 15k on the odometer from a known porsche buddy. Once I get my other tranny out I will see if a new flywheel is in order or not. Needless to say it didn't come out tonight. My wife challenged my old school skills in doctor mario so my time was taken. Maybe tomorrow morning I'll yank it. rotate my flywheel and wiggle my ims bearing. Thanks again.

Jason

That is a smoking deal!!

I buy them out here for $600-800 depending on mileage.

story of my 5 speed using life. I owned 4 of them in various forms of repair during my seasons in Boxster Spec. Getting a 6 speed was one of the best upgrades made to that car, but it was ridiculously expensive.
A complete S car with a blown motor would have been cheaper, both times I've done it...

Painful part of Eric's post?

"Both times" :barf:

Brad, forgive the noob question, but what is the routine for checking these DMFs? I'm about to do IMS and clutch among other things and want to make sure the techs check both the old one, and the new one if replacement is deemed necessary. I have some driveline clunks especially noticeable on 1-2 low speed shifts. Thinking front motor mount or DMF, or...

Before you let the delivery guy walk away.. open the box and put your hand on the face of the new flywheel, twist it. Make sure the bottom half of the flywheel stay's stationary. They arrive crank side down in the box, clutch disc face up. New ones move about 10minutes (think 12o'clock to 2o'clock position)

Bad ones don't move :barf:

Jaay, what kind of groaning sound? My '06 5-spd. just started "groaning" ( no rattle ). I only hear it in first gear, while turning, with even light throttle application. At first I thought is was power steering noise, but it sounds more like gear whine.