Transmission repair

[3_Angels]

2002 Boxster S transmission rebuild. We would like to replace the brass bushing in the first picture. The shaft from part number 2 fits in this bushing however loosely. Porsche sells only the entire assembly of the rear transmission case for over $500 and all the associated parts would have to be swapped over or replaced at considerable effort. Does anyone have a simple or possible solution?

[Spinnaker]

See if the guys at GBox transmissions can help you, there are fairly close to you.
PORSCHE RACING AND STREET GEARBOXES-GBOX Transmission

[JFP in PA]

Originally Posted by 3_Angels

2002 Boxster S transmission rebuild. We would like to replace the brass bushing in the first picture. The shaft from part number 2 fits in this bushing however loosely. Porsche sells only the entire assembly of the rear transmission case for over $500 and all the associated parts would have to be swapped over or replaced at considerable effort. Does anyone have a simple or possible solution?

If Gbox cannot help, you are kind of screwed. This bushing is machined after being pressed in, which requires some special fixtures to accomplish. Porsche has never sold it separately. We have done a couple of these and had to buy the entire tail housing from a dealer to do them.

[rfuerst911sc]

There are shops out there that can perform this repair that is MUCH better than stock. If you have ever seen these bushings they are a real joke they look like a sewing machine thimble . I know this first hand as my 02 S 6 speed box had a severe case of jumping out of 2nd gear. I had no idea of previous history as I purchased this vehicle through a 3rd party that was not told by the previous owner that there was an issue with the transmission. Anyway back on topic. Here in Georgia I was fortunate to find an independent German car repair place that specialized in Porsche's. They had seen many 986/996 transmissions with 2nd gear issues. The shops owner ( a machinist ) developed his own repair using a VERY robust bronze bushing that really makes the OEM bushing look like a joke . He developed a fixture that allows him to " line bore " the case to be able to install the larger bushings. He also found on the net a gasket/seal that fits perfectly making this repair oil tight. The owner told me he's never had one come back for the same condition they are that stout. We did the " while your in there " thing to the tune of $2500.00 but my transmission shifts perfectly and I have zero worries it will occur again. I know Gbox is highly recommended and you should check them out but I would also go to a PCA event and ask around you may get lucky and find a local shop that can do the repair. In my opinion if you are planning on holding onto the car for any length of time repairing the transmission with the OEM bushings is not a very good option. Good luck with the repair and keep in mind 2nd gear is a weak spot on these transmissions.

[3_Angels]

Froze the driven shaft and heated the interference fit parts. Shaft is back together this evening. A friend is cooling the reverse bushing with dry ice. See that the oven temperature of 450 degrees stained my parts.

[3_Angels]

2002 Boxster S transmission rebuild. I haven't located the clear sealant for closing up the transmission case. The clutch plate looked like it could use replacing. A kit including both the clutch plate and the pressure plate was not that much more than just the clutch plate alone, so I ordered the kit. Then I tested the dual mass flywheel and it performed poorly, so I ordered a new one of those. Heck, now as long as I'm in there for that much money and work, I might as well replace the IMS bearing. We have now purchased a DOF (direct oil feed) kit from TuneRS [ Direct Oil Feed (DOF) – 97 – 05 Early Style 986/996/997 | TuneRS Motorsports | Online Shop ] and a set of tools from LN engineering http://lnengineering.com/products/ims/ims-pro-tool-kit-everything-you-need-to-install-a-classic-single-or-dual-row-ims-retrofit.html . This will take us a bit longer to install, but it should maximize the fun content.

[Topless]

You guys are pretty ambitious. When I tossed the pinyon bearing in my trans I just unbolted it and bolted up a used one from a dismantler. Still going strong 3 years long.

[ItsABoxster]

Originally Posted by rfuerst911sc

There are shops out there that can perform this repair that is MUCH better than stock. If you have ever seen these bushings they are a real joke they look like a sewing machine thimble . I know this first hand as my 02 S 6 speed box had a severe case of jumping out of 2nd gear. I had no idea of previous history as I purchased this vehicle through a 3rd party that was not told by the previous owner that there was an issue with the transmission. Anyway back on topic. Here in Georgia I was fortunate to find an independent German car repair place that specialized in Porsche's. They had seen many 986/996 transmissions with 2nd gear issues. The shops owner ( a machinist ) developed his own repair using a VERY robust bronze bushing that really makes the OEM bushing look like a joke . He developed a fixture that allows him to " line bore " the case to be able to install the larger bushings. He also found on the net a gasket/seal that fits perfectly making this repair oil tight. The owner told me he's never had one come back for the same condition they are that stout. We did the " while your in there " thing to the tune of $2500.00 but my transmission shifts perfectly and I have zero worries it will occur again. I know Gbox is highly recommended and you should check them out but I would also go to a PCA event and ask around you may get lucky and find a local shop that can do the repair. In my opinion if you are planning on holding onto the car for any length of time repairing the transmission with the OEM bushings is not a very good option. Good luck with the repair and keep in mind 2nd gear is a weak spot on these transmissions.

Hi,
Is it possible just to replace the shaft sealing ring (OEM 996-303-517-01)? I'm not having any 2nd gear issues just a small leak coming from the gear shift lever. Looks like it would be a tranny-in job over about an hour? Thanks!

[Reebuck1]

Great Post guys !!

[CaliforniaMotorsport]

Originally Posted by 3_Angels

2002 Boxster S transmission rebuild. We would like to replace the brass bushing in the first picture. The shaft from part number 2 fits in this bushing however loosely. Porsche sells only the entire assembly of the rear transmission case for over $500 and all the associated parts would have to be swapped over or replaced at considerable effort. Does anyone have a simple or possible solution?

The factory part number for the shift shaft bushing is 996.303.515.00 and list for about $2.57. We've been replacing them for years.

[Gelbster]

Kudos the California Motor Sports
They post the part number, the price and some advice to help us Forum members and they don't even push their own excellent products - so I will do it for them - go here to see what they do:
PORSCHE 986 BOXSTER TRANSMISSION – California Motorsports Inc
No affiliation - I wish there was ! I need a bunch of their stuff.

[SlowernOlder]

You need to remove the tail housing to replace the seal as the shaft is secured inside the transmission, might as well replace the bushing as it is the reason the seal is leaking.

[ItsABoxster]

Originally Posted by SlowernOlder

You need to remove the tail housing to replace the seal as the shaft is secured inside the transmission, might as well replace the bushing as it is the reason the seal is leaking.

Roger that, Slower! Thanks for that!