2nd gear syncro iffy ???
#1
2nd gear syncro iffy ???
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
#2
Race Director
Ask me in a week or so... Just ordered 15 volume factory repair manual...
Ordered from Sunset Porsche. 1 800 346 0182. Spoke with Luke.
Sincerely,
Macster.
#4
Three Wheelin'
Join Date: Oct 2004
Location: Lesa, Italy & Atlanta, GA
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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.
#5
Race Director
Telephone number for parts but I was giving it to you...
Received the manuals today. All 64lbs of them. Have not had time to look over 5-speed rebuild section.
Sincerely,
Macster.
#6
Race Director
Oh, I think there is no reason to use anything other than the fluid...
Sincerely,
Macster.
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#10
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
Do not worry I will be in the trans myself............... Just looking for anyone that has been there before ...........Thanks
#11
Race Director
Scanned through the factory manual section on manual transmission...
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.
#12
Race Director
Let me add that in looking through the factory manual on the 5-speed...
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.
#13
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.
#15
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