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gearbox removal

Scouser
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Scouser Member

Scouser

Posted
Posted

It's probably a none-starter question but....

Iv'e done it on several cars before but never a 996. But how hard is it to remove and replace the gearbox. Jeff, have you ever done this or seen it been done as a DIY project?

  • Admin
Loren Member

Loren

Posted
  • Admin
Posted

You will need the proper tools, hoists and jack supports.

The engine MUST be supported when removing the transmission.

From the manual:

1. Remove underbody panels (middle and rear).

2. Remove cross member.

3. Support engine with special tool retaining device No. 9624/1 (e.g. engine supporting jack). To do so remove the stabilizer installation and pivot stabilizer forwards.

4. Assemble special tool retaining device No. 9624/1 on the body with the stabilizer fastening screws and adjust pressure screw so that the pressure disc is aligned with the crankcase.

5. Remove drive shaft on transmission side.

6. Separate electrical connection from the reversing light switch.

7. Unclip the hydraulic line for the clutch slave cylinder at the side

transmission case cover.

8. Unscrew clutch slave cylinder suspend on side. Do not remove

hydraulic line.

9. Remove switch cable from the transmission and pull it off the

transmission switch and selector lever.

10. Place transmission jack under the transmission and fasten fixing

strap.

11. Remove transmission container.

12. Remove transmission support.

Note: The transmission can be lower by a maximum of 25 mm to improve

accessibility.

13. Unscrew fastening screws (8) between engine and transmission.

14. Pull transmission to the front and lower.

Scouser Member

Scouser

Posted
  • Author
Posted

Thanks heaps Loren. Some more questions:

This tool 9624/1, can this part be ordered. I.e., joe blow can just walk in and order it? Also I have visions of this being some sort of large scisor jack. Is it a large expensive device? DOn't suppose you have any pics of it.

The transmission jack, again is this a standard jack? But what is the fixing strap you mention in item 10? Sounds like it too is a special jack.

Finally, I take it that these instructions assume the car is up in the air on a hydraulic lift? Or can this be done by taking the car up high on jack stands?

It sounds to me that the most precarious part is ensuring the engine is supported correctly and in the right place. Lowering the gearbox may be a dangerous task too. I guess the big question is, is it really doable as a DIY project?

  • Admin
Loren Member

Loren

Posted
  • Admin
Posted

If you have access to a hoist or pit and a second set of strong hands it is likely doable.

Here is the tool (actually a brace) and how it is used. I would think a well place jack would work well too - except that you have the risk of knocking it when removing the transmission.

trans_tool.gif

trans_brace.gif

Scouser Member

Scouser

Posted
  • Author
Posted

Brilliant Loren. Thanks.

My budy has a metal fabrication plant. I will ask him what he thinks about making this brace. Looks easy enough.

As it happens I do have a pit but it was filled in by the previous owner

and not very well too. I have often thought about cleaning it out.

If I am going to keep this car for the long haul I am starting to think I will have to get serious about DIY. Anyway i will think on it.

Many thanks again.

  • Moderators
Tool Pants Member

Tool Pants

Posted
  • Moderators
Posted

I have removed transmissions from cars and my truck on my driveway for clutch and transmission rebuilds, but never a Boxster. It is something I would not want to try without the car being on a lift since it is so confined in the engine compartment.

I watched Peter remove a Boxster transmission in 25 minutes. For a seal replacement. :o But he has a lot of experience.

The Boxster also has a brace to support the weight of the engine, except it goes on top since we can get to the top of the engine on a Boxster. I have never seen it but there is a drawing of it in the workshop manual. The guys in the shop use an engine jack instead. It is like a very long jack stand that goes from the floor to the bottom of the engine. For the transmission they use a transmission jack.

post-21-1088224166_thumb.jpg

  • Moderators
Tool Pants Member

Tool Pants

Posted
  • Moderators
Posted

The red thing on the far left with the threaded rod is the engine jack. The transmission with the chain around it is on the transmission jack. Not my picture but that is how my dealer does it.

transmission_lift.sized.jpg

Scouser Member

Scouser

Posted
  • Author
Posted

Thanks Jeff for the pics and info. I have my buddy looking into making me the engine mount jig and we are looking into modifying an ajustable acro bar for the engine jack.

One question: how heavy do you reckon the tranny is? two people can lift it?

  • 4 years later...
  • 1 year later...
996noob Member

996noob

Posted
Posted
You will need the proper tools, hoists and jack supports.

The engine MUST be supported when removing the transmission.

From the manual:

1. Remove underbody panels (middle and rear).

2. Remove cross member.

3. Support engine with special tool retaining device No. 9624/1 (e.g. engine supporting jack). To do so remove the stabilizer installation and pivot stabilizer forwards.

4. Assemble special tool retaining device No. 9624/1 on the body with the stabilizer fastening screws and adjust pressure screw so that the pressure disc is aligned with the crankcase.

5. Remove drive shaft on transmission side.

6. Separate electrical connection from the reversing light switch.

7. Unclip the hydraulic line for the clutch slave cylinder at the side

transmission case cover.

8. Unscrew clutch slave cylinder suspend on side. Do not remove

hydraulic line.

9. Remove switch cable from the transmission and pull it off the

transmission switch and selector lever.

10. Place transmission jack under the transmission and fasten fixing

strap.

11. Remove transmission container.

12. Remove transmission support.

Note: The transmission can be lower by a maximum of 25 mm to improve

accessibility.

13. Unscrew fastening screws (8) between engine and transmission.

14. Pull transmission to the front and lower.

Hi Loren,

Do you have the procedure for a Tiptronic?

I would like to change my transmission mounting, so the Tip has to come out.

Thanks!

  • Moderators
RFM Member

RFM

Posted
  • Moderators
Posted

Best buy is a shop or similar manual to prevent you from possible mechanical problems (and money) IMHO.

  • 4 years later...
racerken Member

racerken

Posted
Posted

If you have access to a hoist or pit and a second set of strong hands it is likely doable.

Here is the tool (actually a brace) and how it is used. I would think a well place jack would work well too - except that you have the risk of knocking it when removing the transmission.

trans_tool.gif

trans_brace.gif

Hi Loren, is this bar the same for a 997?

Thanks.

  • Admin
Loren Member

Loren

Posted
  • Admin
Posted

If you have access to a hoist or pit and a second set of strong hands it is likely doable.

Here is the tool (actually a brace) and how it is used. I would think a well place jack would work well too - except that you have the risk of knocking it when removing the transmission.

trans_tool.gif

trans_brace.gif

Hi Loren, is this bar the same for a 997?

Thanks.

Yes, since the engine is basically the same as the 996 it should work fine.

jaekormtb Member

jaekormtb

Posted
Posted

I know I am a bit "shade tree mechanic", but I just did the clutch, IMS and RMS in my 99 C4 using stands and a jack. Safety, common sense, and creativity can lead to success.

post-6798-0-98036100-1394704376_thumb.jp

Paul Grainger Member

Paul Grainger

Posted
Posted

Scouser

I have done this job at home a number of times. The gearbox is quite heavy - one man can lift it but you will need help to position it. I have a scissor ramp in my garage, this lfts the car about 5' above the ground which is plenty of height. I have in the past propped the engine with a piece of wood cut to the correct length - although having seen the fixing brace shown I will make one for next time. I have a cheap multi-vehicle clutch alignment tool, it only cost a tenner of ebay and it does the job perfectly. There is one bolt on the bellhousing that is fiddly to access, I purposefully left this out when re-fitting the box. I have a machine mart transmission jack - also from ebay at a cost of £20.

It really is an easy and straightforward job if you have a lift of some sort. The last time that I did this the whole job took 3.5 hours from start to finish (I replaced my flywheel). I wouldn't tackle it without a second person to help manouvre the gearbox on-and-off though.

Paul G

  • 2 weeks later...
racerken Member

racerken

Posted
Posted

If you have access to a hoist or pit and a second set of strong hands it is likely doable.

Here is the tool (actually a brace) and how it is used. I would think a well place jack would work well too - except that you have the risk of knocking it when removing the transmission.

trans_tool.gif

trans_brace.gif

Hi Loren, is this bar the same for a 997?

Thanks.

Yes, since the engine is basically the same as the 996 it should work fine.

Hi Loren,

Sir Tools makes one for the 996 and costs 179 plus 20 shipping from ebay so I ordered it from one of their resellers ZDMAK. I just test fitted and the 997 sway bar frame mounts are wider than that of the 996. Hence I'm returning it. Sad day.

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