Removal and Replacement

Removing and installing transmission - Boxster S

Tools





Removing and installing transmission G86/20

Removal
1. Remove silencer for the intake system.





2. Hold engine in installation position at the transport bracket using special tools 10-222 A and 9591/1.
3. Remove diagonal braces and sheetmetal cross member.
4. Remove stabilizer.
5. Remove rear silencer. Service and Repair
6. Remove rear cross member (V strut).






7. Remove heat shield.
8. Remove drive shafts at the transmission and protect the shafts against damage (use scrap pieces of hose with a diameter of 30 mm).
9. Disconnect plug connection for the reversing light switch and pull the wire out of the retaining clips.

Warning! The clutch pedal must not be pressed if the slave cylinder has been removed. Danger of injury from flying piston rod. Affix a warning note where it can be seen in the vehicle!

10. Unscrew the clutch slave cylinder and hang up at the side with the hose connected.






11. Lever off shift cables on transmission lever using a commercially available removal tool.






12. Release the support bracket sleeves (press tabs in the direction indicated by the arrow) and carefully pull them out of the bracket.

Note The shift and cables must not be excessively bent or kinked.

13. Place transmission jack under the transmission and fasten fixing strap.
14. Remove transmission support with left and right hydraulic mounts.





Note Fastening nut "C" (M12) must not be undone. Otherwise, the transmission support will be damaged.





15. Unscrew transmission Engine fastening screws. Use a polygon wrench (10 mm, part No. 999.571.052.02) for screw No. 4.
16. Pull transmission to the rear and lower it carefully.

Installation

NoteThe rear cross member (V strut) cannot be fitted if the rear muffler is installed.

Install in reverse order.

1. Clean teeth of the drive shaft and grease with a thin coat of Olista Longtime 3 EP (available as spare part).
2. Check that dowel sleeves are seated perfectly in the crankcase.






3. Carefully insert transmission and tighten the fastening screws using the correct tightening torque. Use a polygon wrench (10mm, part no 999.571052.02) for screw 4

4. install transmission support with left and right hydraulic mounts.
5. Press support bracket sleeves into the holder and lock in place
6. Press shift and selector cables onto transmission lever

No.in fig. screw tightening torque
-1- M12x70 85Nm (63 ftlb)
-2- M12x100 85Nm (63 ftlb)
-3- M12x100 85Nm (63 ftlb)
-4-* M10x50 45Nm (33 ftlb)
-5- M10x50 45Nm (33 ftlb)
-6- M12x50 85Nm (63 ftlb)
-7- M12x70 85Nm (63 ftlb)
-8- M12x70 85Nm (63 ftlb)
*Multiple-tooth nut

7. Fit clutch slave cylinder and tighten fastening screw to a tightening torque of 23 Nm (17 ftlb.).

Note: The bleeder valve must be opened if the piston rod cannot be pushed back manually when the clutch slave cylinder is being installed. Connect a collecting bottle with hose for this purpose.

8. Bleed the clutch system.
9. Insert cable for the reversing-light switch into the retaining clips and make up plug connection.
10. Fit drive shafts on the transmission side.
11. Install heat shield.
12. Install rear cross member (V strut).
13. Install rear silencer

Note: The rear cross member (V strut) cannot be fitted if the rear silencer is installed.

14. Install diagonal braces and sheetmetal cross member.
15. Remove safety device 10-222 a and support device 9591/1 from the engine.
16. Install silencer for the intake system.

Tightening torques