Transmission repair
06-19-2014, 02:38 AM
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Transmission repair
2002 Boxster S transmission rebuild. We would like to replace the brass bushing in the first picture. The shaft from part number 2 fits in this bushing however loosely. Porsche sells only the entire assembly of the rear transmission case for over $500 and all the associated parts would have to be swapped over or replaced at considerable effort. Does anyone have a simple or possible solution?
06-19-2014, 11:25 AM
#2
Race Director
Based on what you wrote, it is not clear the bushing requires replacement. The loose fit may be on purpose.
If you believe the bushing needs to be replaced, clean the area and look for any markings on the bushing. Chances are the bushing is an off the shelf part that once you have the markings you can find a replacement through a bearing supply.
Or you could take the housing to a reputable transmission shop and ask if it can supply you the right bushing, even replace the bushing for you.
Remember you need to remove the old bushing without damaging the very expensive case, then you need to properly install a correct replacement bushing.
If you believe the bushing needs to be replaced, clean the area and look for any markings on the bushing. Chances are the bushing is an off the shelf part that once you have the markings you can find a replacement through a bearing supply.
Or you could take the housing to a reputable transmission shop and ask if it can supply you the right bushing, even replace the bushing for you.
Remember you need to remove the old bushing without damaging the very expensive case, then you need to properly install a correct replacement bushing.
06-19-2014, 03:56 PM
#4
Race Director
But I would only go this route if I couldn't find an off the shelf replacement with a reasonable effort.
BTW, when I had a machine shop a one off cost a pretty penny as it takes about as much work to make one as it does 100.
'course, in a pinch one pays the price for a one off if there is no reasonable alternative.
06-20-2014, 09:45 PM
#5
Drifting
3Angels,
It would be very interesting to learn from you about having your Getrag 466 gearbox rebuilt.The failing parts that are usually mentioned are the two large sealed bearings (16 in your dwg. ?) and second gear.
In a previous thread the cause of the bearing failure indicated was excessive heat that destroys the seals and some discussion of gearbox oil coolers ensued.
The second gear issue seems to be just that it is undersized ?
Dismantling and rebuilding seem to be at the outer limits of diy because of the special puller required and other difficulties. There is very little information about rebuilding the Getrag 466 so it will be very interesting to learn about your repair job if you care to share.
It would be very interesting to learn from you about having your Getrag 466 gearbox rebuilt.The failing parts that are usually mentioned are the two large sealed bearings (16 in your dwg. ?) and second gear.
In a previous thread the cause of the bearing failure indicated was excessive heat that destroys the seals and some discussion of gearbox oil coolers ensued.
The second gear issue seems to be just that it is undersized ?
Dismantling and rebuilding seem to be at the outer limits of diy because of the special puller required and other difficulties. There is very little information about rebuilding the Getrag 466 so it will be very interesting to learn about your repair job if you care to share.
06-22-2014, 02:21 AM
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https://www.facebook.com/photo.php?f...type=1&theater
Notes on FB page reference the PDF we are following. New 2nd gear and cog sleeve assembly are in hand to put back in maybe tomorrow.
Notes on FB page reference the PDF we are following. New 2nd gear and cog sleeve assembly are in hand to put back in maybe tomorrow.
Trending Topics
06-22-2014, 01:06 PM
#8
Race Director
3Angels,
It would be very interesting to learn from you about having your Getrag 466 gearbox rebuilt.The failing parts that are usually mentioned are the two large sealed bearings (16 in your dwg. ?) and second gear.
In a previous thread the cause of the bearing failure indicated was excessive heat that destroys the seals and some discussion of gearbox oil coolers ensued.
The second gear issue seems to be just that it is undersized ?
Dismantling and rebuilding seem to be at the outer limits of diy because of the special puller required and other difficulties. There is very little information about rebuilding the Getrag 466 so it will be very interesting to learn about your repair job if you care to share.
It would be very interesting to learn from you about having your Getrag 466 gearbox rebuilt.The failing parts that are usually mentioned are the two large sealed bearings (16 in your dwg. ?) and second gear.
In a previous thread the cause of the bearing failure indicated was excessive heat that destroys the seals and some discussion of gearbox oil coolers ensued.
The second gear issue seems to be just that it is undersized ?
Dismantling and rebuilding seem to be at the outer limits of diy because of the special puller required and other difficulties. There is very little information about rebuilding the Getrag 466 so it will be very interesting to learn about your repair job if you care to share.
When I did auto repair at my house I had to rent an engine hoist, rent or borrow an engine stand, and for some work I'd farm this out to a shop, like the block and head cleaning, engine cylinder boring, valve and value guide work. I never did any transmission rebuilding but if I had I would have used a reputable transmission shop or automotive machine shop for any press work.
06-22-2014, 01:41 PM
#9
Drifting
I have been trying to "approach" a transmission shop anywhere in Los Angeles for a while with no success.
There are two simple selection criteria.
1. I ask if they are experienced in repairing the Getrag 466.I usually get a clueless response.
2. I visit and look at what they are working on.If I don't see Getrags and at least one 466 ,I abandon the inquiry.
If it is going to be a learning experience, I would rather be the one learning :-).
I have another 2 places to visit and eventually I'll find the place the Porsche/Audi repair shops sub-out their transmission work to.
Meanwhile I suggest it is in the Forum's interest to encourage & help Jim with his project so we can all share in the experience. As our cars accumulate miles, more of them are going to need these repairs ,so future Forum members will benefit from our work.
The estimates I've had for bearings +2nd gear are well over $2000 even with me doing the r&r.
I have had some difficulty even locating a Transmission parts dealer who sells the 466 parts - like National for the bearings?
Anyone got experience with GBOX in Boulder Co ?They are Porsche gearbox specialists.
or anyone know: Alacantar S.Atlantic Blvd Los Angeles
There are two simple selection criteria.
1. I ask if they are experienced in repairing the Getrag 466.I usually get a clueless response.
2. I visit and look at what they are working on.If I don't see Getrags and at least one 466 ,I abandon the inquiry.
If it is going to be a learning experience, I would rather be the one learning :-).
I have another 2 places to visit and eventually I'll find the place the Porsche/Audi repair shops sub-out their transmission work to.
Meanwhile I suggest it is in the Forum's interest to encourage & help Jim with his project so we can all share in the experience. As our cars accumulate miles, more of them are going to need these repairs ,so future Forum members will benefit from our work.
The estimates I've had for bearings +2nd gear are well over $2000 even with me doing the r&r.
I have had some difficulty even locating a Transmission parts dealer who sells the 466 parts - like National for the bearings?
Anyone got experience with GBOX in Boulder Co ?They are Porsche gearbox specialists.
or anyone know: Alacantar S.Atlantic Blvd Los Angeles
06-22-2014, 07:49 PM
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Boxster S transmission repair
Which side goes toward the transmission on seal part 17, A or B? The drawing from a manual seems to show side B in. There is not a consensus from posters so far.
Last edited by 3_Angels; 06-30-2014 at 05:40 PM.
06-22-2014, 09:01 PM
#11
Race Director
I have been trying to "approach" a transmission shop anywhere in Los Angeles for a while with no success.
There are two simple selection criteria.
1. I ask if they are experienced in repairing the Getrag 466.I usually get a clueless response.
2. I visit and look at what they are working on.If I don't see Getrags and at least one 466 ,I abandon the inquiry.
If it is going to be a learning experience, I would rather be the one learning :-).
I have another 2 places to visit and eventually I'll find the place the Porsche/Audi repair shops sub-out their transmission work to.
Meanwhile I suggest it is in the Forum's interest to encourage & help Jim with his project so we can all share in the experience. As our cars accumulate miles, more of them are going to need these repairs ,so future Forum members will benefit from our work.
The estimates I've had for bearings +2nd gear are well over $2000 even with me doing the r&r.
I have had some difficulty even locating a Transmission parts dealer who sells the 466 parts - like National for the bearings?
Anyone got experience with GBOX in Boulder Co ?They are Porsche gearbox specialists.
or anyone know: Alacantar S.Atlantic Blvd Los Angeles
There are two simple selection criteria.
1. I ask if they are experienced in repairing the Getrag 466.I usually get a clueless response.
2. I visit and look at what they are working on.If I don't see Getrags and at least one 466 ,I abandon the inquiry.
If it is going to be a learning experience, I would rather be the one learning :-).
I have another 2 places to visit and eventually I'll find the place the Porsche/Audi repair shops sub-out their transmission work to.
Meanwhile I suggest it is in the Forum's interest to encourage & help Jim with his project so we can all share in the experience. As our cars accumulate miles, more of them are going to need these repairs ,so future Forum members will benefit from our work.
The estimates I've had for bearings +2nd gear are well over $2000 even with me doing the r&r.
I have had some difficulty even locating a Transmission parts dealer who sells the 466 parts - like National for the bearings?
Anyone got experience with GBOX in Boulder Co ?They are Porsche gearbox specialists.
or anyone know: Alacantar S.Atlantic Blvd Los Angeles
I'm certainly not trying to be discouraging but if I don't know an answer to a question I can't/won't ad-lib or guess as the wrong answer can be very costly.
It has been my SOP in the past in similar situations that if it wasn't clear to me how a bushing or bearing or another assembly went together to either use how the bushing/bearing or assembly was installed and came apart, refer to a manual or how to book, ask a tech or specialist.
If none of the above are available, then I'm at a loss.
I just remembered a Porsche tech I know has an Audi transmission out of a car and on his bench. It has been sitting there for some time now. I sort of recall the hangup/delay is the cost of at least one gear set (2nd?). (I spotted the busted gear teeth from a mile away.) He says this (whatever "this" is) is a rather common failure. Wished I'd snapped some pics.
Oh, you might try www.partsgeek.com. I got a hit on "getrag 466" at that site and the link took me to a selection of transmission parts for Audi transmissions. Trouble is one might need the part number or part number to find anything.
Which suggests too that parts for a getrag 466 might be available from/ or through an Audi dealer parts department.
Last edited by Macster; 06-22-2014 at 09:02 PM. Reason: Fixed auto corrected get rag to getrag.
06-24-2014, 10:05 PM
#14
Drifting
A machine shop would have some of the tools/equipment, but not the knowledge of the gearbox.
For example ,the bearings are a press fit on the shafts. That's correct -no splines. Can you imagine the force required to remove and re-fit the bearings? And you are limited to only 2 times!
The press required is 80-100 tons!Freezer overnight?
For example ,the bearings are a press fit on the shafts. That's correct -no splines. Can you imagine the force required to remove and re-fit the bearings? And you are limited to only 2 times!
The press required is 80-100 tons!Freezer overnight?
Last edited by Schnell Gelb; 06-25-2014 at 12:35 PM.
06-25-2014, 01:05 AM
#15
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Transmission repair
Installed a new second gear with its synchronizer. Reinstalled first and reverse. Picture shows a friend helping me cool the reverse bushing with dry ice. The driven shaft was cooled with dry ice and the interference fit parts were heated to 450 degrees in the oven. The 1-2 shifting sleeve cogs had to persuaded a bit; everything else fell right onto the shaft. Tomorrow we start assembling the shifting forks.