DDK - Die Deutschen Klassiker

I know there are a number of boxster fans on ddk, so hoping to get some help and advice for a friend who purchased a boxster S a few months back. It's a 2000 manual S model and has an issue with 2nd gear. I believe there is a known weakness in these gear boxes and 2nd is particularly an issue. To date two other gear boxes have been fitted both with the same issue. Obvious fix is a full gearbox rebuild, could anyone either recommend a supplier who could supply and guarantee a replacement box at a reasonable price or recommend someone/garage in the Essex area who can help. Friend bought the car which is a lower miler for around £8k, there not in a position to throw 000s at trying to fix the issue.

Thanks
Mark

Hello, never heard of weak 2 gears, but it is a gear that takes a lot of work on all cars. I have an 86K mile 987.2 which is the 6 speed manual box, maybe the 5 speeder is weaker?

I suggest 2 ways forward:

Wayne on here may see your post, he races these cars hard and has been through a few boxes so may know a good rebuild man.
Secondly, from the Porsche Club GB they list 2 specialists in Essex:

ADH Braintree
info@adhporsche.co.uk
01376 384785
They list gearbox rebuilds in their skill-set. Worth a call?

West Park Lodge

info@porschespecialistservices.co.uk
www.porschespecialistservices.co.uk

I do now know these specialists as I live in the West Midlands.

Hope this helps your friend.

Yes this is a known issue on Boxster 6 speeds, and seems quite common..was on my fairly long list of reasons to buy a 2.5 over an 2.7/3.2, the 5 speed box doesn't have the issue.

If it is a problem going in to 2nd from cold, yes either live with it or a rebuild I believe. If it is popping out if 2nd there is a detent available which is an easier fix as far as I know, applies to 996 also. I don't know whether anyone can guarantee a used box not to develop the issue, but Hartech or La Rose might be a start to speak to.

Before changing gearboxes change the oil to a mineral/non synthetic gearbox oil? Might help the synchro engage if that is the issue? Might give your friend a little more time to think about what to do?

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This^^^ Boxsters went through (or still are in) a period of being cheap enough to attract 'cheap' owners. The 'oil is oil' types. It isn't. I've 'rescued' boxes before by draining, refilling, sometimes slightly overfilling, and using them.

I assume he’s checked / changed gear change cables

I changed the oil in my 03 S over the summer and the 1st to 2nd movement when cold is definitely better.

Speak to Mike at Sports and Classics..Experts in gearbox issues.

https://sportsandclassic.com/porsche-gearbox-repairs/

Sorry, just seen this. As someone said the 5 speeder from the 2.5/ early 2.7 is pretty straightforward and fault free. Not easily interchangeable with an S, cables, shifter unit and output flanges / driveshafts all different.

Your friend must have been super unlucky to have 3 boxes with the same fault, even conceding the known weakness. I tried to get a 996 gearbox looked at recently and it seemed mighty expensive - few people touch them. One of them I found had a ‘how much does it cost’ in their Q&A and it was £5-6k for even a modest build, so not worth it on an £8k car.

There is no adjustment on the cables and usually the only issues are them snapping completely or the plastic locking cap falling off (a997 part) at the gear lever, both of which leave you in the gear you were in, so it is pretty unlikely to be an issue with the car. The hydraulic clutch is very difficult to bleed because it is low in the car and needs both pressure bleeding and the car raising really high if possible- that could cause a poor shift exacerbating a slightly wonky 2nd gear.

Worth phoning the contacts and getting an idea, in the hope that it can be done more cheaply than I found. Boxes are in abundance and cheap, and changing one takes c3 hours, and is pretty simple DIY job so worth another box I would say

Hope that helps in some way
Wayne


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There is a chap on Facebook called IAN PECK, specialises in all sorts of gearboxes, is based in the West Midlands & who seems to have a very good reputation and good customer base, and often puts videos on of the repairs with faults he finds.
Seems no gearbox is a problem for him.
Might be worth giving him a call if near to you?

This popped up on my feed earlier.

May or may not the right version but in case it’s useful….

https://youtu.be/J-A_G7TUBIU?si=RZz5sMOcqu6jEyRC

That's a good video.
Complicated things aren't they.