Output Shaft Removal for 2002 Boxster S G86 Transmission - 986 Forum - The Community for Porsche Boxster & Cayman Owners

AR|Groundzero · 12-19-2011, 04:47 PM

I was having the dreaded 2nd gear slip so my friend and I took the transmission out of the car for a closer inspection. We have the transmission out and on a bench and were able to identify the issue. The issue is in fact the synchro and possibly 2nd gear.

Now here is the question. We have been unable to get the tapered bearing out of the top of the output shaft in order to get to 2nd gear. Does anyone know how to get this tapered bearing out? I have attached a photo for your review.

jcb986 · 12-20-2011, 05:01 AM

They are either pressed on are held in place by a snap ring...snap rings should be a certain points to hold assemblies in there right position. Get a diagram be fore you start disassembling it.

AR|Groundzero · 12-30-2011, 10:33 PM

We figured it out. We had already removed the snap rings and 2 spacers. The gears needed to be pulled out using a kukko gear puller in 2 stages. In stage one, first gear and all components above the gear were removed. In stage two, second gear and all remaining components were removed. A significant amount of force was required to remove the gear puller drive screws via a pneumatic impact wrench set to 110 psi. The estimated torque required to move the bearings along the shaft is calculated at 305 foot pounds which would generate 3660 pounds of force per inch. The resultant force on the ½ inch shaft of the gear pullers is 7,320 pounds or 3.66 tons of force.

We removed the gears and noticed that second gear was damaged. We replaced the gear and syncro and reassembled. We were sure to test the transmission on the bench before we reinstalled it. While the transmission was out we replaced the IMS, Rear Main Seal, Clutch, and CV Boots.

We are working on a complete article detailing our adventure.

In all the job took about 5 days. But my Boxster shifts like butter and has never driven better.

nefarious986 · 12-30-2011, 10:52 PM

*thumbs up* & awaiting write-up .. not that I'll ever have the balls to attempt this myself .. but love to read about other ppl's exploits ..

wanna986 · 01-25-2012, 05:44 PM

Quote:

Originally Posted by AR|Groundzero

We are working on a complete article detailing our adventure.

Congrats and please do take the time to do the write-up. Where did you source the puller?

AR|Groundzero · 01-25-2012, 06:29 PM

I got lucky and sourced the puller from an area independant mechanic shop on loan. Because of the space between the gears (see picture in the post below) you have to have a gear puller with thin feet. I used a Kukko gear puller.

Update, I have been driving the car for a month and it is absolutely perfect!

AR|Groundzero · 01-25-2012, 06:35 PM

Oops, I almost forgot. Because of the hollow shaft in the Boxster S transmission, we had to create a tool to allow the puller to have somewhere to apply the downforce.

I am still working on the article. There is a lot of data so it is taking some time. In the meantime if you have any questions please ask.

AR|Groundzero · 01-25-2012, 06:55 PM

I have had some inquiries about the parts I replaced during the project. Here is the list:

• RMS
• IMS
• CV Boots
• 2nd Gear
• 2nd Gear Syncro
• 2nd Gear Selector Sleeve
• Clutch
• Pressure Plate
• Throwout Bearing
• Brake Switch
• Primed and Painted the Exhaust
• HID Driving Lights (Bonus)

landrovered · 01-26-2012, 04:49 PM

Very happy to see this I am looking at doing the same on my car. If you don't mind me asking...What was the cost of the transmission parts ?

AR|Groundzero · 01-26-2012, 06:06 PM

The transmission parts cost as follows:

Gear 996.302.942.00 $385
Shift Sleeve 996.304.061.02 $450
Syncro Sleeve 996.304.611.00 $130

AR|Groundzero · 03-15-2012, 07:43 AM

Thank you for your patience. Here is the article. Let me know if you have any questions.

Meir · 03-15-2012, 10:47 AM

this is awesome. file saved.

my 2nd gear is fine (for now) but i'm sure some people want to know how much its going to cost them to ship their transmission to you.

AR|Groundzero · 03-15-2012, 11:47 AM

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

YeeHaw!

Escy · 10-18-2015, 03:13 PM

This question if for someone that's opened up a G86.20. How hard is it to separate the bell housing from the rest of the gearbox? I'm considering the feasibility of trying to change the bell housing for an Audi one. When you split the box, if I remove the differential at the same time, can the gearset be removed as a unit or does it need to be stripped down completely?