Transmission shock!!!!!

[huskerinmo]

I have a 2002 911 Cab. Today I got the call from the forign car repair place and they tell me I need a "new" used transmission for $10,000 installed or a new one for $13,000 that comes with a new clutch. I asked what it would cost if I didn't get the clutch and they said $400 less. The problem with the car when I took it in was that it would upshift just fine through all 6 gears but would not downshift into second gear unless I let the RPM get down below 1000. I am ready to get a new car and don't want to sink $10,000 into this car when it is only worth about $25,000. Am I getting a fair estimate or does anyone have any better ideas...Thanks for all your help...Jesse

P.S. Got advice from 911 tech board that I should also try posting over here...Thanks

[Matt Monson]

Step 1. Call a towing service, and get your car out of whatever shop it's at. That's totally reckoculous and indicative of a shop that has no business working on your car or is trying to screw you.

Step 2. Fill out your profile so I know who to tell you to have your car delivered to once you get it out of the bad shop.

Step 3. Call California Motorsports. 928- 855-5755 Ask to speak to Roger Brown. They are an expert on that gearbox. Should run you around $3000 to get it rebuild, including fixing the notorious 2nd gear pop out issue. Figure $200-250 shipping each way.

If there's anything else I can do to help, just let me know.

Regards,

Matt Monson
Guard Transmission LLC
303-530-1094

[Steve@Rennsport]

Excellent advice from Matt!!!! (as usual)

Make sure your car is not at R-V.

[johnnywishbone]

Originally Posted by Steve@Rennsport

Excellent advice from Matt!!!! (as usual)

Make sure your car is not at R-V.

agree. that was really well done.

[BYprodriver]

Originally Posted by Matt Monson

Step 1. Call a towing service, and get your car out of whatever shop it's at. That's totally reckoculous and indicative of a shop that has no business working on your car or is trying to screw you.

Step 2. Fill out your profile so I know who to tell you to have your car delivered to once you get it out of the bad shop.

Step 3. Call California Motorsports. 928- 855-5755 Ask to speak to Roger Brown. They are an expert on that gearbox. Should run you around $3000 to get it rebuild, including fixing the notorious 2nd gear pop out issue. Figure $200-250 shipping each way.

If there's anything else I can do to help, just let me know.

Regards,

Matt Monson
Guard Transmission LLC
303-530-1094

+1 on all of the above

[huskerinmo]

Matt thaks for the advice...I can drive it out as it will go through all of the gears no problem on the way up. Problem doesn't start until I go down shift and get to 2nd gear...Found a way though of just soft push into second on down shift with RPMS below 1000 and wating about 1.5 seconds before hitting the gas. I am in St. Louis. I got the break downtoday an there was some information the forgot to mention in the price that could be deducted $699.00 for a clutch disc they wont know if they need it until they tear it all down. Also $994.63 for new Flywheel also wont know til tear down. they charged me $162.00 to check the car out. used transaxle $$5,600 Labor $1,200 Drain and fill trans fluid 168.00 Flywheel bolts $18.00 sub total 8,667.63 tax 597.00 tot. 9,265.35 90 DAY WARRANTY ON TRANSMISSION.

[huskerinmo]

Thanks everyone for all your help!! it is nice to find such an active board.
OK here is the funny part. I just went to pick the car up. They say we will pull it up fornt. Doesn't come fo a whil so I peak around the side and they are jumping my car?? I don't find anything on when they give it to me and just mark it up to dumb luck. I drive care home park it in the garage turn the key off as always and throw the keys on the seat. I come back down 20 minutes later and the clock, mileage and digital spedo are still on."GREAT"!! So I take it back up to them and they check it out and tell me I have to lock the car for them to turn off. I say I have been doing this process for years and it has never been a problem. I get the I don't know look and I say I will just bring it back next week!!

[Matt Monson]

One other bit of advice... Beware of any local shop that tells you they can rebuild this gearbox, even if they are a Porsche specialty shop or one of the ones recommended in your other thread in 911 Tech.

The G96 gearbox is not like other Getrag gearboxes and even if the tech does ten G50s a year it doesn't mean he'll know how to rebuild your gearbox. For starters it requires a 50 ton press to get it apart. There's no way around this. The gears are press fit, and not slip fit like other Getrag gearboxes. There's a variety of other little issues and fixes that are specific to this gearbox. If the tech tells you that he can rebuild it, make sure you aren't about to be his guinea pig on this project and that he has in fact done these boxes before.

Furthermore, the 2nd gear pop-out and downshifting issue you are facing is very common to this gearbox. It's a design defect. It can be fixed by someone in the know. If you buy a used gearbox from a dismantler, as was suggested by some in your other thread, you have no guarantee that you won't have the issue again in 6 months. Or worse yet, you might get a second gearbox with the same problem, and warranty or not, you'll end up paying the labor and shipping to return it to the dismantler and go through months of brain damage trying to make your car right. Properly repaired and rebuilt by a technician who knows this box and you'll not see a repeat of your current issues.

I live by the motto, do it right, do it once. There's no shortcuts here. There's no easy way out.

Regards,

Matt

[carrera911/996]

Originally Posted by Matt Monson

Step 1. Call a towing service, and get your car out of whatever shop it's at. That's totally reckoculous and indicative of a shop that has no business working on your car or is trying to screw you.

Step 2. Fill out your profile so I know who to tell you to have your car delivered to once you get it out of the bad shop.

Step 3. Call California Motorsports. 928- 855-5755 Ask to speak to Roger Brown. They are an expert on that gearbox. Should run you around $3000 to get it rebuild, including fixing the notorious 2nd gear pop out issue. Figure $200-250 shipping each way.

If there's anything else I can do to help, just let me know.

Regards,

Matt Monson
Guard Transmission LLC
303-530-1094

Hello,

I saw tghat you have some knowledge about this cars so please if you can help me...I have a 911/996 2003 carrera and last summer i was running with it out of oil but not so long to damage it too bad.So i tried to rebuild the engine so i have bought all the damaged pieces.The axle,bearings,pomps and everything.Now i put all in order but i hardly try to find someone which know how to set up the distribution because i hared that is an order how to put the crankshafts and the chain.Please someone help me i am in a desperate situation because i have broken one crankshaft already because i didn't put them well in order.I have made the order for new one and please let me know if you have someone wich knows how to set distribution at 996.

thank you very much.

[FPB111]

Carrera911/996,
Did you check the other thread that you started on this?

look at post #19 on this thread
Dual Camshaft Position Sensor Errors Need Help! - Page 2 - Rennlist Discussion Forums



"It sounds like you need to check CAM (all 4 of them) timing.

You might try these folks for literature-help
Porsche servicing, repairs, engine rebuilds, reconditioned wishbones and cars for sale - near Bolton, North West England.
also maybe post on the rentech forum
996 Series (Carrera, Carrera 4, Carrera 4S, Targa) - RennTech.org Forums

and
996 Forum - Rennlist Discussion Forums
look at post #19 on this thread
http://forums.rennlist.com/rennforums/996-forum/613620-dual-camshaft-position-sensor-errors-need-help-2.html"

[rcwaldo]

Originally Posted by Matt Monson

One other bit of advice... Beware of any local shop that tells you they can rebuild this gearbox, even if they are a Porsche specialty shop or one of the ones recommended in your other thread in 911 Tech.

The G96 gearbox is not like other Getrag gearboxes and even if the tech does ten G50s a year it doesn't mean he'll know how to rebuild your gearbox. For starters it requires a 50 ton press to get it apart. There's no way around this. The gears are press fit, and not slip fit like other Getrag gearboxes. There's a variety of other little issues and fixes that are specific to this gearbox. If the tech tells you that he can rebuild it, make sure you aren't about to be his guinea pig on this project and that he has in fact done these boxes before.

Furthermore, the 2nd gear pop-out and downshifting issue you are facing is very common to this gearbox. It's a design defect. It can be fixed by someone in the know. If you buy a used gearbox from a dismantler, as was suggested by some in your other thread, you have no guarantee that you won't have the issue again in 6 months. Or worse yet, you might get a second gearbox with the same problem, and warranty or not, you'll end up paying the labor and shipping to return it to the dismantler and go through months of brain damage trying to make your car right. Properly repaired and rebuilt by a technician who knows this box and you'll not see a repeat of your current issues.

I live by the motto, do it right, do it once. There's no shortcuts here. There's no easy way out.

Regards,

Matt

Ditto what Matt says.

3rd,4th,5th and 6th (pinion gears) are interference fit to the pinion shaft. It is possible to rebuild these as the G96 is quite simple to disassemble compared to the G50/G64 box. The difficulty is making the press tooling to get the top gears off the pinion shaft to change the pinion head bearing, which many cars are now exhibiting the 'whine' from pitted pinion bearings.

Anyone who rebuilds the G96 box must gain access to the pinion bearing and its races for inspection -- to do this the top gears must be removed.