Output Shaft Removal for 2002 Boxster S G86 Transmission

[AR|Groundzero]

lol, that is funny. It was all worth it and it is everytime I put the car in second and accelerate!

YeeHaw!

[wanna986]

You've made a significant contribution to the data base!

[AR|Groundzero]

I love to help the Boxster community. I have saved a lot of time and money from others articles.

Thanks for the encouraging words.

[Amille28]

Does anyone have a copy of the article. Rebuilding 2nd gear on a 996 and need to do the same job. Thanks!

[AR|Groundzero]

Thanks for reaching out. I have 20k miles on the car since the repair and it has NEVER slipped a gear and is still running as smooth as butter.

Here is a Dropbox link to all documents I used as well as an article that my friend and I put together to describe the process.

Boxster Transmission Repair Documents

Let me know if you need anything and happy repairing!

[Gelbster]

Thanks so much for putting the time and effort into publishing all this info.It was a lot of extra work for the benefit of the 996/Boxster community.As far as I know this is the only such diy guide to this important project.
Would you happen to be selling an old 944 strut part?? I need one and when I am done I'll pass it on to the next Forum member who needs it .I'll also add to your excellent write up.
I am trying the pulling with a Harbor Freight 12 ton puller.It will be interesting to see if it will fit .Certainly a little grinding will be required to fit. Yes, it was a lot cheaper than the German Kuko puller!But only if it works.
Surprised not to see the sealed bearings in your parts purchased list. I think I recall you bought the parts from Eric at Gbox?
Thanks once again for your work.
Mod: That work should be preserved in a special section on this Forum ?

[Gelbster]

Here is a photo of the jaw/leg of the Harbor Freight 12t puller. If you compare it with the Kukko puller ,you'll see the difficulty of fitting the very large 'claw' in the tiny space around the gear cluster. I suspect that if you grind enough material off the claw to fit,it will weaken the claw to the point where it will break before the gear set can be extracted. Possibly, the fact that it uses 3 legs,not two like the Kukko - may help?
I am wondering if we are using the correct tool to pull the gears and bearings off. A bearing separator would easily fit in the tight space but I have not tried it.Too weak?
Another problem with the HF 12t puller is that it is very heavy/awkward to set up and is dangerously powerful.It could do a lot of damage to that hollow shaft!

[Gelbster]

Originally Posted by Amille28

Does anyone have a copy of the article. Rebuilding 2nd gear on a 996 and need to do the same job. Thanks!

Amile,
I am not an expert but:
AFAIK ,the 6 speed transaxle in the Boxster S & the 996 is largely the same internally.It is the Getrag G466.That is the # for the whole transaxle not just the gearbox. The rear of the gearbox case is different because of the different mounting.
Just be careful you don't confuse the 5 speed G86.00 &G86.01 in the base Boxster with the G86.02 6 speed in the S. They are not the same.
The 996/Carrera gearbox is referred to as G96.00 & G96.01
The G96.50 and up are totally different(GT3 etc)
Getrag - Wikipedia, the free encyclopedia
The authority on this subject is Eric at GBOX:
PORSCHE RACING AND STREET GEARBOXES-GBOX Transmission
PORSCHE 986 BOXSTER TRANSAXLE SPECIFICATIONS – California Motorsports Inc
It would be good to have a definitive correction to all these part numbers!

[AR|Groundzero]

I am glad that I can maybe fill in some knowledge gaps. I am here to ensure that these marvels of engineering stay on the road and are not given a bad rap because of the mishaps of others. BTW, I believe that 3 cars, besides my own, are back on the road due to this forum and the knowledge it contains.

Now on to business...

While the Harbor Freight puller is quite a bit cheaper than the Kukko, you would probably do yourself a favor by buying one on eBay and then selling it when you are done. I had tried many other pullers before just biting the bullet and finding a Kukko I could use. Make sure to get the one with the slender arms and extension. From what I remember, both are necessary.

As far as the strut assembly, I have one but I don't really want to sell it. Mostly for sentimental reasons. I would be fine with you using it but how would I ensure that I get it back? Nothing personal....for some reason being backed into a corner and figuring out something that seemed impossible has left an indelible mark

If anyone knows anyone that can cut thick plexiglass into a circle please let me know. I want to make a coaster out of the old 2nd gear that I removed from my Boxster for my work desk.

Please let me know if there is anyway that I can help.

Happy Motoring!

[Gelbster]

Great info-thanks
FYI to others the correct(????) Kukko part number is "KK20-1+S" The S = slender arms. The cost seems to be around $300 on EBay.
This is a 2 arm puller. I am still confused about why a 3 arm puller would not be better?

[JayG]

Originally Posted by AR|Groundzero

If anyone knows anyone that can cut thick plexiglass into a circle please let me know. I want to make a coaster out of the old 2nd gear that I removed from my Boxster for my work desk.

Please let me know if there is anyway that I can help.

Happy Motoring!

Go to a plastic store. Most of them can cut as well