smartrepair

I bought a remanufactured gearbox from a company called GBOX. The price was about $3500 including the shipping in the continental US. They have all the models.

, and no need to send the core back (maybe they´´ll give a discount if you do send it back).

The box has some reinforced parts.

The web site is: gboxweb.com

Kare, Spain

Thanks again Kare! Got my car back with the repaired gearbox from GBox and it feels great and even seems to shift a lot smoother! :)

Great! Enjoy your car....

What would be the recommended DME for my 3.8 S engine swap ( my car is MY99 C2 cabrio). I have possibility to get resonable priced 997S DME or 996 7.8 version.

What is the principal difference on these DMEs?

I know that the more advanced the car gets, more complicated the modifications. So I was wondering if the 997 S DME is too complicated for my car...

I also need to purchase the A/C control unit, and the ABS control unit. Do the latest model 996 ones (for 3.6 engine) work with the 997 S DME?

And the last question, can the CAN bus cables be made, or do I have tobuy them from Porsche?

Thanks and saludos

Kare

Don't take this the wrong way, but if you don't even know what the DME is you are probably in way over your head. Fitting a 3.6 to an early car is not a mechanical problem, it is purely electronics.

I have provided the details on how it can be done with either a piggy back controller or the factory way in several posts on this site, use the search function and you will find the details are there.

Todd

Hi

I found pretty cheap shocks and springs from 2004 turbo coupe (front ones are grey single dot, and white/red together; the rear ones are blue single dot and brown/white together, the shocks are all with brown dots). Are they a std ones for a Turbo?

Do they fit my MY99 cabrio?

And the main thing...how the suspension will be altered?

Thanks

Kare

Hi

Any idea which springs are installed in my MY99 US model 996 C2 cabrio. The color dots are as follows:

Front: White single dot, brown and yellow dots together

Rear: Grey (white?) single dot, brown and red dots together.

My option sticker under the hood is destroyed, so I cannot consult that either. I could not see any numbers on the springs...

Thanks guys!

Kare

Hi

I need the part number.

Also please let me know if that part is used in other Porsches.

Thanks in advance!

Kare

Any help would be greatly appreciated i have a 99' carrera and would like install a 3.6 in it (already have it) Ive been reading but cant get solid answers what do i need to make it work i mean for a daily driving car i also read something about aftermarket controller boxes for the variocam plus were would i get something like that and remapping the ecu is that something that only the dealer does or can a specified shop do it any help would be greatly appreciated and please feel free to elaborate as much as possible on what is best

Hi there

I´m doing a bit similar conversion (a MY99 996 and 3.8 engine from 2006 Carrera S). In the end I decided to buy a 7.8 DME, but have not found time to find out how to plug the DME into the old DME harness (the connectors are different). The engine harness plugs, after a very short initial verification, are very similar, the old plug obviously lacks the variocam controller line. I contacted one company in South Africa (who are the manufacturers of a piggybag controller), but in the end I decided to go for the route to replace the DME, ABS controller, instrument cluster etc. to have a factory alike installation - just like Todd has made with his Boxter (a MY99, now with 3.6 engine)

Due to too much work right now, I don´t have time to do anything, but my idea is to install the engine in the end of February...

I will post any progress, but if somebody is doing the same before........

Saludos

Kare

http://cgi.ebay.com/ebaymotors/Wheels-Tire...sspagenameZWDVW

would these fit? is BSA a good brand?

As far as I know, they have different offset, and won´t fit...

Nice set anyhow!

Kare

Hi all, I am thinking about pulling the trigger on a set of wheels. They are

19x8.5 et52 front and 19x10 et52 rear. Hubcentric fit. Any issues with this setup? what is the thickest tire I can put on these wheels without rubbing/fitment issues? (Car is a 1999 996 C4, stock suspension)

I found them on ebay, anyone dealt with eurotechwheels?

Thanks.

Hi

I bought a set of 19" chromed alu wheels for my MY99 996 cabrio from Eurotechwheels.

Very, very nice set, and the quality of the chrome is outstanding. Obviously no idea on a long run...

egards

Kare

While I eventually changed my car to the returnless fuel system, it isn't necessary.

Todd

I have the 3.8 engine with all the fuel rails etc.

And MY99 996. I was wondering (uh, could it be so simple,,???) to install a aftermarket fuel pressure regulator between the 3.8 engine fuel inlet and the fuel line from the fuel pum, and connect the "wastegate" from the pressure regulator to the fuel return line.

Is this possible???

Kare

Todd

How did you solved the returnless fuel line issues?

Regards

Kare

Reliability of 996 Engines

Be sure and check the photos of the tear down.

Loren,

Thank you, I looked over the pics and began to read the article. Do you know if there are special tools that are need to split the crank case and deal with pulling the pistons? Additionally, any special tools to put it back together again? Is this a DIY adventure?

Thanks

Hi

I did the rebuilding of a 3.4 engine by myself. I have no previous experience on those things, but had the Porsche workshopmanual. Without it it would have been impossible to do it.

The only "special" tool required was a home made piston circlip installation tool, which I made from two plastic tubes. See attached picture. I cannot remembre the diameters of the tubes, but I think the bigger one was about 3/4", and the inside one was just able to slide inside. I had to sand away a bit for the exterior tube for it to enter the piston installation hole.

I looked the exact position of the circlip, and made a blue line into the "installation tool" to be able to line it correctly to the piston. The small cut you can see in the exterior tube is where the circlip´s hook has to be placed. It was a bit problematic to put the circlip inside, but I found out that even it was not completely perpendicular to the tube, it went into it´s place without problems. Just a light hit to the inner tube, and the circlip went into. Just press the exterior tube tightly against the piston.

I was surprised how easy it was,in the end, after months of investigation how in heaven I´m going to get the circlips in....

When I opened the engine, I removed the cams together with the variocam unit, so here was no need to adjust them. The chains were OK. I also made a small thing to hold the cams inplace when the valve cover was removed.

Otherwise there were no big issues...

Saludos

Kare

Smartrepair...

Thanks for the insight. I see the picture of your tool, the pipe in a pipe however can you explain a little more, how exactly do you use it? Can you define the "circlip"? And finally where does one acquire a "shopmanual"?

The circlip is a metallic ring keeping the piston pin (connects connection rod and piston together) on its place . To use the installation tool,first line the connectig rod with the instalation hole,install the piston and insert the piston pin. The circlip is placed inside the outer installation tool tube,with the hook inside the cut.

The tube is then pressed tightly against the piston, lining the installation tools blue line with the piston´s circlip opening. Then a firm hit into the iner tube to install the circlip.

I bought my shopmanual from Ebay, however it was an illegal copy. Porsche sells the legal copies, but with very hefty price. Send me a PM, maybe I could help you.

Kare

Hello again experts! I have a 1999 996-series Carrera 4 Coupe, and to make a long sob story short I need a new 6-speed manual transmission. I have had 2 mechanics tell me that they would not recommend trying to rebuild mine, so I was hoping someone here could give me some suggestions as to where to find a used one. I have already contacted Oklahoma Foreign and Parts Heaven and neither of them currently have any used ones in stock. Thanks SO much and hopefully I'll hear back from someone! :)

I bought a remanufactured gearbox from a company called GBOX. The price was about $3500 including the shipping in the continental US. They have all the models.

, and no need to send the core back (maybe they´´ll give a discount if you do send it back).

The box has some reinforced parts.

The web site is: gboxweb.com

Kare, Spain

Reliability of 996 Engines

Be sure and check the photos of the tear down.

Loren,

Thank you, I looked over the pics and began to read the article. Do you know if there are special tools that are need to split the crank case and deal with pulling the pistons? Additionally, any special tools to put it back together again? Is this a DIY adventure?

Thanks

Hi

I did the rebuilding of a 3.4 engine by myself. I have no previous experience on those things, but had the Porsche workshopmanual. Without it it would have been impossible to do it.

The only "special" tool required was a home made piston circlip installation tool, which I made from two plastic tubes. See attached picture. I cannot remembre the diameters of the tubes, but I think the bigger one was about 3/4", and the inside one was just able to slide inside. I had to sand away a bit for the exterior tube for it to enter the piston installation hole.

I looked the exact position of the circlip, and made a blue line into the "installation tool" to be able to line it correctly to the piston. The small cut you can see in the exterior tube is where the circlip´s hook has to be placed. It was a bit problematic to put the circlip inside, but I found out that even it was not completely perpendicular to the tube, it went into it´s place without problems. Just a light hit to the inner tube, and the circlip went into. Just press the exterior tube tightly against the piston.

I was surprised how easy it was,in the end, after months of investigation how in heaven I´m going to get the circlips in....

When I opened the engine, I removed the cams together with the variocam unit, so here was no need to adjust them. The chains were OK. I also made a small thing to hold the cams inplace when the valve cover was removed.

Otherwise there were no big issues...

Saludos

Kare

ziiz996,

Sorry you're dealing with such a mess.

If you get the wiring diagrams for the two cars (the 3.4L and 3.6L) you can look at where each pin in the connector goes in both cases and write it down. Then do the conversion by swapping the wires appropriately. It will require some time and patience but it shouldn't be too difficult.

I would concentrate on looking at the wiring diagrams. Anything that communicates via CAN bus (the things mentioned earlier in this thread) will have to be replaced and connected to the CAN bus wires. It's not that complicated, really. You may have to tell the DME (using a PST2 or PIWIS) about the new CAN bus items. (I've never done it but that makes sense since they are coded).

Hi there

I´m still looking for different options for my 996 MY99 cabrio engine swap from 3.4 to 997 3.8 one.

I have the complete engine, with engine harness. Now I found a guy who would sell me a brand new 2002 onwards instrument cluster, 7.8 DME, airbag control unit, 2 remote keys, inmobilizer unit, air cond unit, rear and front control unit and complete 997 car wiring harness for about $2300. Looks like a very interesting option,or what do you think?

He said this would be a "plug and play" for my engine. But... LOren said in one of thew posts that changing the engine harness is a complicated job. If I choose this route, what elese do I need for the set up to work? The ABS unit, or...????

And what will happen with my convertible top controlling? How is the control unit wired, to the DME, I suppose?

Saludos,

Kare

Savannah interior. Once a tan, now kind of a mustard yellow. Is there any product or technique to correct this?

GOOD

BAD

Depends....if the color change is due to the effect of sun, the only method is to have the interior redyed.

But quite likely it´s just dirty. Good cleaning will make wonders already, although it may not bring it exactly to the original tone.

Try leather cleaning and protecting products like LEXOL. For the plastic parts sometimes a simple household product like dishwashersoap does wonders. I cannot remeber any specific cleaner for the plastics.

Saludos,

Kare

After reading your forum topic on the Durametric fault diagnostic tester I decided to Purchase one.

I have connected it to my 1997 Boxster 2.5 which is a Europe car.

One of the faults that it has shown up is

P1397 Camshaft position (CPM) sensor 2. Signal implausible or short to ground.

I have spent many hours searching for this sensor which should be located at the top front of the left side cylinder head. I eventually removed the inlet manifold to try and find it but without success.

I have found the one on the right side of the engine but on the left side I can see the place on the casting where it should be but there is no hole or drilling where it should fit.

I telephoned the Porsche Center and I was told that some of the early cars only had one?

I cant understand how the system can work with only one.

Does anyone know if this is correct.

Yours with his Porsche in bits

Lionel

Yep, the ROW cars have only one CPM sensor. I don´t know why...Funny that Durametric doesn´t know that,maybe it´s time that somebody should tell them?

Saludos

Kare

Looking at your little sheet you don't seem to realize that there are 26 pins on each of the old instrument connectors and 32 on each of the new ones. You also don't seem to realize how much work this was for me to figure all of this out.

For the pin removal/ installation for the cluster connectors you don't actually need any special tools, just remove the outer coloured casing and it is quite obvious how to remove the pins with a small pin or screwdriver.

Todd

So Sorry Todd!

:oops: I managed to leave out the extra column for the second bank of connectors on the sheet/table that I sent you.

I was trying to make it simpler by making it look more like the connectors. (L and R side). Feel free to add columns or extra rows per table if you prefer.

I TOTALLY understand that this is not a small job. But I really thought that you must had gone through the diagrams first, wrote down the conversion charts of you re-connections on a sheet/table of some sort, then re-wired, instead of re-wiring directly from the diagrams!

Thanks,

Jacomo.

Hi guys

How is the this conversion chart project going forward? I am also in need to do this job...

Does anybody has the 7.8 DME and 2002 onwards instrument cluster wiring diagrams for 996?

Saludos,

Kare

I have a 3.4 engine in my MY98 >Boxter. When installing the engine, I reused the original Boxter intake hose, cutting it and adding short extension. At the same time I took the "muffler" away. In my opinion the sound is much better.

We were comparing a stock Boxter S sound and my (stock) exhaust sound, and mine was much deeper, much better! I have desnorkeled the intake as well...

Kare, Spain

Should have first looked at the pictures of my own 2.5 before responding. The intake "muffler" is bolted to the lower nut.

I wonder how much louder or cooler the intake noise would sound with that muffler removed and the hole plugged with my desnorkeled boxster... Ill try to find a plug solution and let you all know someday.

Today my coolant was thrown out partially. The coolant was cold, and looks like it was leaking at passeger side, from upper part of the engine. However, the coolant reservoir in trunk was hot! And when opening the cap, there was no pressure.

I added some coolant fluid the day before (it was below the lower limit) , and when opening the cap the was pressure.

It was about 1 litre of water which came out.

What can cause this????? A faulty cap? There was no coolant below the rear trunk carpet...

Leaky caps or cracked tanks - sorry but that is 99% of the leaks.

Hi

I have the 3.4 ROW engine installed in my MY98 Boxter (US model). When the converson was done, there was one tube which was broken (came so when I bought the engine), as I didn,t know to where it is supposed to be connected, so I just plugged it.

Any idea what is the other end? The tube is attached to the intake manifold, over cylinder bank 2.

Thanks

Kare

The 99's had a problem with the clutch release lever. If you did not replace it with the new design, that is very likely your problem. It get's hung up at times, especially on quick clutch engagement. There is a TSB covering this. The TSB decribes it as a noise problem only so Porshe did not have to issue a recall.

Clutch can be changed without dropping engine.

I also don't understand why on earth you would install an unsprung clutch kit on the 996. You sure are placing alot of unecessary stress on various componants for no reason.

The car has a new 400 hp 3.8 x51 motor so we needed to upgrade to a stronger clutch, we went with unsprung and full face organic as sachs told us with the flex in the drivetrian inheirant in 99-2000 car's we should be fine. I will ask about the lever thanks.

Hi

Did you do the 3.8 swap by yourself? I want to do the same, but still collecting information how to do it (egas, variocam + controller, returnless fuel pump etc.). How did you solve these issues?

Best regards

Kare

Is anyone familiar with this item. Supposedly can be homemade from 3/4" or 1" aluminum and installed for less than $20. Stiffens the rear plate that ties the rear subframes together. This is supposed to be a super improvement on the track with no downsides. I'm wondering if it is practical and has a noticable effect on agressive street driving. I won't be getting on the track, but would like to tighten and improve the 986's handling if it can be done for less than $20. Like, why not???

Seems like if it were really as good as they say, there would be numerous offerings for a bar and everyone would want/have one.

Bob

Can somebody send a photo of this mod?

Cheers

Kare

Hi

This article is not written by Todd.

The author works in a company doing the engine swaps, but I cannot remember the name nor the company name. I´ve been searching all the forums I know (I think there are more than 10 of them), but no success...

Hi guys

I´ve been spending hours and hours in internet searching information about how to install a 3.6/3.8l engine into a early Boxter/996.

I came across one article, but when I saved it, only one part was succesful. I have no idea from where I found it.

Does somebody recognise this article? I remember it was a guy in the USA, who workis in a company doing the engine swaps for Boxters.

All the best,

Kare, Spain

Hi Kare

Not exactly sure where the article is but do a search on user tholyoak - he wrote it! Todd is a very helpful and knowledgeable guy as well. If you cant find it here, have a look on the boxster racing board, he may have posted it there.

Keep us posted on your progress as I'm looking to go down the same track.

Cheers

Dennis

Hi guys

I´ve been spending hours and hours in internet searching information about how to install a 3.6/3.8l engine into a early Boxter/996.

I came across one article, but when I saved it, only one part was succesful. I have no idea from where I found it.

Does somebody recognise this article? I remember it was a guy in the USA, who workis in a company doing the engine swaps for Boxters.

All the best,

Kare, Spain

Hi

Do you find the car´s ride much more harder with 19" wheels?

I´m considering buying new wheels, and trying to decide between 18" and 19" ones.

I don´t want to shake my bladder too rigorously!

Pls let us know

Kare (terveiset Espanjasta)