Boxster Layshaft damage

[nzlandy]

First post so hello to everybody

I have a 97 Boxster 986, 2.5, 5sp manual (New Zealand)

Just want to share this to see if anyone else had this problem

I had noticed (but not thought too much about it) 1st gear was getting noiser, other gears were fine, gear change was fine too

Took it in for a regular service and the Porsche service guys commented on it and suggested a bearing and I should schedule a time to strip the gearbox to see what was going on

Also told me to nurse it until then

So I started saving for a big bill haha

some time later I had it booked in and had the gearbox stripped

Bearings were fine,

Syncros fine

Layshaft 1st gear teeth had big pitting in several teeth

All other gear clusters where fine

Have attached the photos of the teeth

Questions

Is this normal wear ? ha

What do your reckon caused this wear?

Is this a manuafacturing fault?

Would appreciate your feedback

Any Boxster owers had similar issues?

regards

andy

[greerj1]

Andy:

What does the mating gear look like? It looks like a manufacturing defect seeing how the porous area appears to be below the profile of the gear tooth. How much was the new shaft?

Jim Greer

[pk2]

That'll do it in spades. I think greer put his finger on it, some kind of metallurgical flaw.

Regards, PK

[nzlandy]

Hi Jim

The mated gear was fine, only this layshaft and the end bearings needed to be replaced

All other parts went back into the box

Price for the shaft was about $1700 NZD from memory+ labour

I wonder if Porsche will come to the party and helpout out on this?

cheers

andy

Andy:

What does the mating gear look like? It looks like a manufacturing defect seeing how the porous area appears to be below the profile of the gear tooth. How much was the new shaft?

Jim Greer

[Bill_SoCal]

First post so hello to everybody

I have a 97 Boxster 986, 2.5, 5sp manual (New Zealand)

Just want to share this to see if anyone else had this problem

I had noticed (but not thought too much about it) 1st gear was getting noiser, other gears were fine, gear change was fine too

Took it in for a regular service and the Porsche service guys commented on it and suggested a bearing and I should schedule a time to strip the gearbox to see what was going on

Also told me to nurse it until then

So I started saving for a big bill haha

some time later I had it booked in and had the gearbox stripped

Bearings were fine,

Syncros fine

Layshaft 1st gear teeth had big pitting in several teeth

All other gear clusters where fine

Have attached the photos of the teeth

Questions

Is this normal wear ? ha

What do your reckon caused this wear?

Is this a manuafacturing fault?

Would appreciate your feedback

Any Boxster owers had similar issues?

regards

andy

:welcome:

Andy, this doesn't look like wear to me...more like a defect inherent to the machining/mfg process. Just curious...how many miles on your gear box?

All the best,

Bill B)

[nzlandy]

Hi

I had is fixed at about 100,000km

Not sure exactly when the problem staed as it sneaked up on me

But from 90,000km onwards for sure

Everybody who as seen it thinks it a defect in the steel and not normal

Its not like Porsche is going to come back to me as say sorry about that, here's a new gearbox for your trouble

But is nicer to know what actually went wrong

I have also had new clutch, new front rotors and pads, new front bushs replaced, but all of these where really worn and needed it

maybe I drive it hard, but I don't think so

cheers

andy