12-19-2011, 04:47 PM
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#1
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Output Shaft Removal for 2002 Boxster S G86 Transmission
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.
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12-20-2011, 05:01 AM
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#2
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Registered User
Join Date: Apr 2009
Location: Orlando
Posts: 1,266
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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.
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2000 S/3.2 Liter/Tiptronic/Boxster S Sport Package/Cruise Control/Slate Grey Metallic
Red Special Leather Interior/Red Floor Mats/Red Hand Painted Instrument Dials/Roll Bar/Windstop
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12-30-2011, 10:33 PM
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#3
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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2nd Gear Fixed!
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.
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12-30-2011, 10:52 PM
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#4
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Registered User
Join Date: Jul 2008
Location: San Jose, CA
Posts: 207
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*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 ..
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01-25-2012, 05:44 PM
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#5
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Registered User
Join Date: May 2006
Location: Toronto
Posts: 277
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Quote:
Originally Posted by AR|Groundzero
We are working on a complete article detailing our adventure.
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Congrats and please do take the time to do the write-up. Where did you source the puller?
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01-25-2012, 06:29 PM
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#6
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Gear Puller
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!
Last edited by AR|Groundzero; 01-25-2012 at 06:59 PM.
Reason: Added another picture
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01-25-2012, 06:35 PM
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#7
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Custom Tool
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.
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01-25-2012, 06:55 PM
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#8
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Parts Replaced
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)
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01-26-2012, 04:49 PM
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#9
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Registered User
Join Date: Nov 2009
Location: Madison, Georgia
Posts: 1,012
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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 ?
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2001 Boxster S 3.6L, Zeintop
"Calling upon my years of experience, I froze at the controls." - Stirling Moss
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01-26-2012, 06:06 PM
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#10
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Parts Cost
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
Last edited by AR|Groundzero; 01-26-2012 at 06:24 PM.
Reason: Forgot a Part!
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03-15-2012, 07:43 AM
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#11
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Article Finally Done
Thank you for your patience. Here is the article. Let me know if you have any questions.
Last edited by AR|Groundzero; 03-18-2012 at 06:19 PM.
Reason: Had to pull the article for now. I will keep you posted.
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03-15-2012, 10:47 AM
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#12
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1999 base
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,617
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Wow!
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.
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03-15-2012, 11:47 AM
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#13
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Registered User
Join Date: Dec 2010
Location: Louisville
Posts: 19
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Worth the effort
lol, that is funny. It was all worth it and it is everytime I put the car in second and accelerate!
YeeHaw!
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10-18-2015, 03:13 PM
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#14
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Registered User
Join Date: Oct 2015
Location: Cardiff, UK
Posts: 107
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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?
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