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Old 10-30-2015, 12:42 AM   #1
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Gearbox 8620-1003 for Boxtser S 04/2003

Hello,

I need your help for the following topic

My Boxster S (B 04/2003 WPOZZZ98Z4U641290, gearbox G8620-103) has problems with the second gear.

From the two options to repair the box or to buy a used one I want to choose the scond possibility.

I found a lot of gear boxes in the internet, but nearly every Boxster S box is from the 2002er model (252 PS, not 260).
Could I use this box as well or is it a must to use the G8620-103 ?

Many thx in advance for your help !

Best
Sven

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Old 10-30-2015, 12:51 AM   #2
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Hi Sven,

before swapping or repairing the gearbox:
Is the problem only present when the gearbox is cold?
What ATF did you use in your gearbox?
Did you check the front motor mount and is it OK?

Regards
Markus
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Old 10-30-2015, 07:39 AM   #3
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G8620-00x = 6-speed gearbox S-Models 2000-2004

x is either 1 or 2:
-001 is non-limited slip differential (LSD)
-002 is for the LSD
This is from a simple search here.
Search also for 'Detent' - 15 minute job !
Also check cables for correct operation -especially at the gearbox-easy to do.
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Old 11-01-2015, 02:28 AM   #4
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Thanks for your feedback.
I have only problems with 2nd gear, when it`s cold no chance to get it in, when the gearbox is warm I get the 2nd gear in but it jumps automatically jumps out.
I don`t know which ATF is used because I don`t change it since I bought the Boxster 2 years ago.

Regarding the type.
-001 and -002 is clear, but for what stands -103 ?
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Old 11-01-2015, 04:32 AM   #5
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Hi Sven,

i've attached a sheet that shows the logic of the 986 transmission number. So you should recheck your transmission number first.



Transmission types and number by model years (geman model years) - see attachment.

If second gear doesn't get in when transmission is cold, in most caes the front motor mount is worn (had the same problem) and poeple don't use the right transmission oil. There is a special oil from Shell that should be used with that 6 speed transmission. Any other oils in general cause problems. Problem is that you can not buy it in Germany in sizes less than 20 litres. So i did a group buy.

2nd gear, hard to shift after tranny oil change
2nd gear, hard to shift after tranny oil change
2nd gear, hard to shift after tranny oil change
http://986forum.com/forums/general-discussions/55977-2nd-gear-hard-shift-after-tranny-oil-change-2.html

If the 2nd gear doesn't go in because of worn front motor mount and wrong oil and people force to get it in, transmission will be ruined within short time (Synchronringe). So it starts to pop out. Search for the detend solution Gelbster postet, which can help if the 2nd gear isn't fully ruined.

Changed Motor Mount @ 95k
Changed Motor Mount @ 95k

If you want to replace the gearbox also replace the front motor mount and also check the gearbox mounts.

Regards
Markus
Attached Images
 

Last edited by Smallblock454; 11-01-2015 at 04:51 AM.
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Old 11-01-2015, 07:48 AM   #6
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Sven,
Marcus and I have posted epic amounts of research on this subject in the previous posts he kindly linked for you. His info is worth a lot. He knows more about this subject (& has shared it !) than many Porsche Tech Departments.
I am acknowledging that because you seem to have lost interest.
Here is a helpful article on the subject from Pelican:
Porsche 911 Carrera Gbox Second Gear Shift Detent Installation - 996 (1998-2005) - 997 (2005-2012) - Pelican Parts Technical Article
$200:
http://www.ebay.com/itm/PORSCHE-TRANSMISSION-996-or-BOXSTER-DETENT-NEW-FIXES-2ND-GEAR-Pop-Out-/151517255422?hash=item234721d6fe:m:m1FHVX0IfU9prwM oY_p80Eg&vxp=mtr
Cheaper from Erik Johnson:
http://www.renntrack.com/forums/showthread.php?1278-Detent-DIY

Last edited by Gelbster; 11-01-2015 at 09:27 AM.
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Old 11-01-2015, 08:01 AM   #7
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Hi Gelbster,
I`m suprised about the huge number of information !
I`ve to read it all and have to discuss with a friend of mine who owns a garage, to discuss what is the best way to proceed.
Many many thx !!!
Best
Sven
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Old 11-01-2015, 08:15 AM   #8
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For what it's worth I can vouch for the detent modification. 2nd would every once in awhile pop out and this mod solved the issue permanently. Good luck of getting the issue fixed. As suggested, start with the easy to fix/cheaper possible solutions first before going with the expensive transmission replacement route. Even if you have to replace the trans the other items should be looked into.
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Old 11-01-2015, 09:30 AM   #9
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But if you drive to much after the 2nd gear cluster starts to wear, the detent will not save you.
Replacing the 2nd gear cluster is a really difficult/expensive job. Detent should(imho) be considered wise PM
Erik Johnson has the best price for it.
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Old 11-01-2015, 05:36 PM   #10
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I did the detent on my 2000S a few years and about 12K miles ago. It completely solved the occasional popping out of second gear issue.

Full disclosure, motor mount and gear oil had already been changed when I did my 90K mile service.
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Old 02-27-2017, 08:16 AM   #11
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Note there is now a new,much improved version of the detent -see CMS -aka California Motor Sports and others.

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