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Manual gearbox: repair or replace?


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Hello everybody,

I have a 1999 996 C2 with manual transmission with 47K miles and I have problems to lock the second gear, particularly when the gearbox is cold (little improvements when properly warmed). I have to pull the shift pretty tight before releasing the clutch, otherwise it won't work. So I have the following questions:

- I made some research in the forum and found out that apprently Porsche doesn't sell spare parts for gearboxes, meaning that replacing the whole thing is the last option. Is it still true today? If so, any idea of current cost?

- Any clue of potential cause(s) of the problem, other than worn out synchro?

- Does anyone ever had this problem and improved/fixed the situation by changing the transaxle oil? I read some good comments on Royal Purple, is it worth giving it a try? Any other recommendation?

- I have subscribed an extended warranty contract with a company called Easycare for my car. Do you think this will be covered, or will they put the blame on me or previous owners?

Thanks in advance for your help.

Laurent

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as suggested, I would try changing fluid. I was experiencing similar problems on my 99 C2 and changed the transaxle to BG fluid with a friction modifier. Cured the problem entirely.

The transaxles can be rebuilt as noted by Richard. Porsche recently started selling parts and there is an independent that has been selling 2d gear syncros for a while. His ads run in Panorama all the time. There is also a thread on this topic that I posted in a while back.

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Have you changed fluid? Have you visually inspected both the cables on the side of the tranny and the shifter cables/mechanism for binding? I would eliminate these tems as the cause before even thinking that the problem is internal.

+1

The cables can become detached where the housing is held in alignment at the transmission and cause difficult shifting. A quick and easy fix you can do yourself. Don't overlook this as many who work on these cars forget to properly seat the cables and difficult shifting is the result.

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Hi guys,

Thanks to all of you for your quick replies. :thumbup:

First thing I will do is change the oil, sounds like a good thing no matter what.

Regarding inspecting "both the cables on the side of the tranny and the shifter cables/mechanism for binding", does anyone have pictures showing where to look at and how things should or should not look like?

At last, if none of this works and that the syncros must be replaced, I checked the Porsche part catalogue (https://techinfo.porsche.com/techinfo/VFModuleManager?Type=MainFrameSet) which doesn't mention these parts (unless I didn't look at the right pages). I then tried to google "porsche second gear syncro". It led me to this link on Ebay:

http://cgi.ebay.com/ebaymotors/Porsche-996...VQQcmdZViewItem

Sounds like a reasonnably priced alternative, provided that I can find someone who can install the parts properly and, of course, this is the real problem...

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Has anyone on the forum replaced the 1st to second synchromesh? Is it a difficult task? Are any specialist tools required? I have previously stripped and rebuilt manual and auto 'boxes without any major problems - my change from 1st to second is very notchy and I am contemplating this job myself.

Paul G

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A friend of mine has done quite a few rebuilds on G96 gearboxes. All I can tell you is that he had to have special tooling made to remove the gears and his hydraulic press is close to the limit when pressing off the gears. The synchros are very expensive - Porsche jacked up the price just after releasing the parts - about £150 (GBP) each for 1st and 2nd gear.

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I am interested to see how you follow through with this I will be sending mine to Power Haus shortly if I cannot figure out why I am having this problem. I have t-shot this thing to death and came to the conclusion that if indeed it were the Synchros then I could not even with the clutch depresed get the shifter to go into it's spot without grinding(all shift speeds tried). The only time I get grinding is when I release the clutch it sounds like there just isn't enough surface area touching to handle the torque of the engine and it pulls away, as though it were never really engaged all the way. I did notice a problem with an odd flexible grommet coming out of the doghouse directly abouve the shifter linkage( like the cord re-enforcements on power tools), but have not had the time to investigate it as of yet. Oh yea I tried the Royal Purple, but it made no difference, I now have the B&G fluid in there it has made a noticeable difference in the fluidity of the tranny but has not cured my ailment. I am leaning towards a mechanical problem with mine, so your results may differ. Best of luck!

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If it really sticks only when cold does it bother you that much? My 997 with Sports shift option is very stiff in 1 and 2 when cold. I just double clutch before going into first and sometimes second. Goes in like butter and its easier on the transmission.

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If it really sticks only when cold does it bother you that much? My 997 with Sports shift option is very stiff in 1 and 2 when cold. I just double clutch before going into first and sometimes second. Goes in like butter and its easier on the transmission.

Well yea it does bother me as it is not normal. It does occassionally lead to it grinding sometimes and I do not like grinding anytime. It won't be too big of an issue in the warmer times. I am just very precautious when shifting and for the love of Pete man this is a 911 not a 78 Datsun. I just need a free day when it is not raining to get under the car and get to the bottom of this and if I cannot get it done before I head back overseas it is coming off and going to a shop.

There is a meager 75kmls on this 99 and it has a mere 2 door dings from people with no respect for others. I really love this car it has every option I was looking for and it is just gorgeous. Full Leather, full CF, tuned coilover suspension, Champion $6,500 wheels, Notchy B&M SS, full body kit and the seems to be rare violet metallic paint. I looked for a few years to find a Porsche that I really liked and this was the one of many that caught my eye. So I want it to be right. I am not a Multi-millionaire yet, so for now I take care of the things I have. Until then I'll do my best.

P.S. Your 997 is new or very close to new so you know this condition exists. I bought this car when it was warm and I had no idea this condition existed until it became really cold. =(

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