UGH - Clutch or tranny problems
 

Spent the weekend with my wife at Sonoma Raceway. Did 12 combined sessions in the car and everything was flawless. This am - get the car backed out of the trailer and go to take it for a quick spin to turn it around to put in the garage and have a tough time getting into first. Then couldn't get into second. Drive it a bit and barely get it back into first and then third. Limp it home and then it goes into gear but doesn't move - clutch in or out. Smell a bit of clutch but not sure what is going on. Push it into the garage. Have my buddy move the shifter - and the shafts seem to move on the transmission - so the cables seem to be working.

Think it must be the clutch or a syncro. Maybe the clutch slave?Didn't see any fluid but didn't look to hard.

UGH.

Definitely sounds like a clutch problem. Check the slave cylinder first, as clutches usually give warning before they go out (slipping, chattering, etc).

Yeah - none of that. Going to definitely check the master and slave. Thanks.

Finally got under the car today. I'm still baffled. The shifter will shift back and forth between first and second but that's it - won't shift reverse or 3-6. Clutch doesn't really feel odd. Thinking the smell was from having to move it in 3rd gear when I originally had the issue come up while driving it. Checked the cables and attachments and they are moving but the selector on the transmissions doesn't want to move when trying any gears other than 1-2. I'm now thinking the transmission is the problem. It was rebuilt in 2013 right before I bought the car - so I initially ruled that out. However - I can't see how this is a clutch problem when I can shift my Cayman S (daily driver) into all gears with the clutch in or out.

My next step would be to drain the trans fluid and check the magnetic fill plug for debris. That may give you some clues...

My money is on pressure plate or release lever, my pressure plate went suddenly like yours but do the other checks first before pulling your tranny.

At this point it's going to the shop. It's the first thing I'll have them do.

They drained the fluid and found debris. Waiting to see after they pull the trans.

I found that buying a good used 5-spd trans (under $500) was a LOT cheaper than having a shop rebuild my original trans ($1,200+). The 6-spd is quite a bit more expensive so that model might be worth the labor to repair.

Yup six speeds are pricier - plus I don't know if this transmission is a "stock" Boxster S six speed or was modified in any way when the original owner bad it rebuilt in 2013. Most say to replace with a Cayman S six speed but the gearing is slightly different and those are about $4-5k. I'm waiting to assess the damage.

Damage is - shifter fork snapped in two. Damaged the 1 and 2 dog gears. Awaiting final damage assessment in terms of dollars.......

Pulling off the 2nd gear and replacing it is not something the average shop can do. They would usually have to send the whole shaft out to a very specialized gearbox repair place. It is easy to cause a lot of expensive extra damage if an inexperienced tech tries generic methods on this 6 speed gearbox.The 5 speed is easier and completely different.
So my advice would be to take the entire gearbox to a competent gearbox specialist who has 'done' many of this specific gearbox.
It will be expensive but a damage/disaster will be worse. Just the parts are eye wateringly expensive.
There are 2 diy write-ups that were successful.There are several other "I'm gonna fix my 'box" threads that died before the reassembly stage and the OP disappeared.
So I suggest you ask here for gearbox repair specialists who are known to be competent. One of the common systems is to ship it in an old cooler box to Colorado. Let's see if others recommend those guys.
Good Luck and keep us updated on what you decide to do and how it turns out?

The shop I used was very competent and yes the final cost was ridiculously more expensive than imagined. However - I'm confident they did a good job. Car shifts so much better than it ever has.

Sorry to hear about your gearbox issues. What shop did you end up using?

If you have the 6 speed, you may want to install the 2nd gear detent while it is out. I realize that it would not have helped in this case as you had a shift fork break, but it will give a better engagement of the gears for the future.

Let me know if you would like one. I just had a batch made up and still have 8 of them left.

$150.00 including shipping.

Best Regards,

Erik Johnson
The Race Line
(720) 899-6005 phone

Hi Erik - I used Ron at IPB Autosport in Sacramento. Trans is back in by now. He did do the shim that was part of a TSB a while ago.