g86.20 rebuild

[ftp19601960]

Does anyone know how to push off loose gears from input shaft? Should I press off all at once using loose 5th gear as support?

[clemsonc]

Sorry, I can't providing any answer to your question above. I am just curious if you used any special tool to open the case of the transmission. If so, what is the name of the tool, and where can I find it.

I have three broken trannys from a 2.5 Boxster (SpecBoxster).

Clemson

[ftp19601960]

I did not use any special tools so far. I have just 20T press and therefore I 'outsourced' gear disassembling to local Porsche tunes for $116 bringing them shafts. Right now I'm researching for bearings/rings for reasonable price. For pinion bearings I will use VW 0A3311133. For input shaft I'm thinking about sourcing original FAG 572548C from China or using a pair such as TIMKEN 2MM207WICRDUL. Gear/Sleeve/rings seem to be unique I have to pay Porsche for labeling (I might check physical dimensions of Audi's 0A2311283 sets) .

[Scnell Gelb]

There were a number of posts on gearbox overhaul :
Transmission repair - 986 Forum - for Porsche Boxster Owners and Others
There are several follow up posts that you could find in "Search" that may help you.
To prevent the bearings failing again do you plan to add a cooler? That has been covered also.
You are obviously a whiz at sourcing ,so you could do a diy version of this:?
TRS Transmission Oil Cooler Kit | TuneRS Motorsports | Online Shop
These guys also sell useful clips:
TRS Shift Cable Security Clips for 986/996
There are also two gizmos to prevent 2nd gear pop-out. One by CMS and one by gbox:
2ND GEAR POP-OUT UPGRADE-GBOX Transmission
Then there is the Numeric shifter & shifter cable upgrade :
Quality Racing Products
Yes, you can spend a fortune on this gearbox! So it will be interesting to read what you decide is worthwhile.

[ftp19601960]

The first post deals only with 2nd loose gear replacement. Very simple task. I need full overhaul (I'm still waiting for the shop to remove fixed gears, I have no big press). Sure thing I'm not expert but GBox detent seems like expensive wodoo for me: the solution for who don't want to open/fix gear box. I would guess that smaller roller would allow bigger swing(?) During my naive examination I found that rings seem to be in very good shape but teeth on 2ng gear are gone. Loose/worn synchro rings are supposed to block engagement and prevent teeth damage: did not happen. Getrag 466 seems to have slightly different asymmetric teeth design for 2nd gear. 466 has the same sealed pinion bearings but different open main shaft bearings. My guess I don't need pump/cooler. I'm not racer I need just street transmission. My '00 passat ZF 5 speed works as good clock for its 130K. I wish I have the same for Boxster.

[Scnell Gelb]

If you search for other posts by that Poster ,you.ll find more details. Most was on Rennlist IIRC.

[wanderzz]

Was this ever completed? How did it turn out? I have a 466 out of my Cayman S that I have to do some rebuild work on.

[wanderzz]

I still need to disassemble it and see for myself what needs to be done and look into what can be done.

[ftp19601960]

I have no experience with it but probably some parts you can get by shopping for Audi transmission of the same kind.
2004 Audi S4 6-AT 4.2L Drive shaft gears and shafts 6 speed manual transmission for 4 wheel drive 2,7ltr. 3,0l 4.2ltr. 2.0/3.0ltr 4.2ltr.

[wanderzz]

Great info. I will take a look. Thanks!

[CTCH]

Hey there, any updates on this? Does anyone know where to buy spare parts from? Does anyone have a PDF with the spare parts? Would be grreatly appreciated