davepnola

Anyone can give me the procedure to replace 2nd gear syncronizer? What parts are needed and will need a big press and torches to heat gears, etc..... Thanks for your response , and yes I have been into manual transmissions before, just not 986 ........... Davepnola

Macster

for Boxster -- 97 to 04 for $350 and approx. $25 shipping. 64lbs worth of manuals...

Ordered from Sunset Porsche. 1 800 346 0182. Spoke with Luke.

Sincerely,

Macster.

davepnola

Thanks I guess the tele number is for the Parts Hey ? Also what about using Syncro mesh fluid that GM puts out for the trans.........?

insite

you need an 80 ton (no typo) press to disassemble / reassemble the five speed. this is according to a mechanic at cogscogs while i was up there picking up a replacement tranny. they don't have a press that strong, so they don't rebuild these units.

Macster

if you were interested in buying the manuals I spoke of.

Received the manuals today. All 64lbs of them. Have not had time to look over 5-speed rebuild section.

Sincerely,

Macster.

Macster

recommended by Porsche. My '02 has over 203,000 miles on its 5-speed and is on the original synchros (and clutch too which is of course not affected by the fluid used in the tranny). Porsche tranny fluid has done ok by me.

Sincerely,

Macster.

insite

i tried redline MT-90 and Swepco 201. the Swepco is really good; especially when cold. i actually trashed a ring & pinion while running the the MT-90.

blinkwatt

I loved Redline MT-90 on my 99'.

The Swepco 201 is okay on my 01' six speed. You can easily tell when the tranny is cold though,compared to OEM.

grey ghost

yeah just got mine back with a new trans for my 2004 Se, took them 26 days to decide to
give me a new one.

thanks Rob.

davepnola

Ok this car is 01 non S and every is scared of going into the trans , even the Local Dealers,..............




Do not worry I will be in the trans myself............... Just looking for anyone that has been there before ...........Thanks

Macster

disassembly and assembly and see nothing scary. No mention of any requirement for an 80 ton press. Several places it mentioned heating the part or parts to 100C before assembly.

Even if one is needed it is a pretty poor auto repair shop that doesn't have an 80 ton press or has access to one at another shop. If you find you need a press, ideally you want to know before you start, check Yellow Pages for a list of say large automobile machine shops or general machine shops and call around until you locate a shop that has such a press and will accept press jobs.

(When I worked as a machinist we took in press jobs. Had two large hydraulic presses, one at least 80 tons (inside the building) and a much larger press located outside the shop building on driveway that ran along side the length of the shop building. Also, one could assemble some pretty tight fitting parts by heating one part and cooling -- we used dry ice in acetone -- to cool the other part. Some times parts with quite a considerable interference fit at the same temperature were a loose fit with the parts heated/cooled properly. Use heavy insulated gloves if you have to handle hot or *cold* parts!)

If you have done other manual transmissions I don't think the Porsche transmission would be all that difficult. All modern manual transmissions are pretty much the same internally.

Take lots of pictures during disassembly to note any and all spacer, collar, bearing, shim, washer, etc. order on the various shafts so reassembly is less prone to error. If any collar, etc. asymetrical, note too which side faces which direction.

Sincerely,

Macster.

Macster

transmission I don't think you're going to be able to assemble this without this manual (group 3) of the factory manual set cause there are spacings of assemblies that require measurement and possible adjustment.

Without knowing which ones are which, and what the measurements should be... I don't think you'll have a good chance (and given the time/effort/cost, you'd want a 100% chance) of meeting with success.

Sincerely,

Macster.

PTEC

The five speeds dont require the 40 ton press. Those we shipped to dealers specifically to do repairs on the Boxster S and 996 Getrag six speed units. That being said, I wouldnt attempt any repairs without having the shop manual.

davepnola

i have the repair manual, will I need the special tools ??? Thanks trans is on the ground and ready to be opened.

davepnola

Ok trans is apart, though I need a special tool to remove the input shaft front bearing tool # VAG 1582 , 1582/2 though I wonder if i can tap on the front of the shaft with rubber mallet and push the shaft out of the bearing?? Anyone have that tool , all syncros besides 1st are really burnt , though second is toast