Porsche Boxster Technical Manual

www.WorkshopManuals.co.
uk
TechnicalManual
-.8e;~s:;TL.,,-
Technicallnformation
Contents:
Group 3
Transmission,manualtransmission
WKD 483 521
Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk
Boxster Foreword
Foreword
The workshop documentationfor the Boxster model has the designation "Boxster" Technical Manual
and contains Technical Information as well as instructions on Repairs.
Theintegrationof the technicalinformationpublishedin the "Boxster"TechnicalManualwith the

descriptivematteron repairsprovidesthe userwith a complexreferencework that combinesinto one
bookassociatedor cross-referenced materialof relevanceto workshopsandoriginatingfrom various
informationmedia.
The "Boxster"Technical Manualconsists of 15 folders, subdividedinto the following Groups

0 Entire vehicle -General
0 Diagnosis,part 1 (up to Repair Group 45) *1
0 Diagnosis,part 2 (as of Repair Group 69) *2
1 Engine,part 1 {up to Repair Group 13) *3
1 Engine,part 2 (as of Repair Group 15) *4
2 Fuel, exhaust,engine electronics
3 Transmission,manualtransmission
3 Transmission,automatic transmission
4 Runninggear
5 Body
6 Body equipment,exterior
7 Body equipment,interior
8/ 9 Air conditioning/ Electrics
9 Circuit diagrams, part 1 (up to and includingthe '99 model) *5
9 Circuit diagrams, part 2 (as of the '00 model) *6
*1 The two folders with Group 0 are to be regarded as one folder; i.e. file the "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group0 -Diagnosis, part 1"
(up to Repair Group 45).
*2
Thesecond folder "Group0 -Diagnosis, part 2" (as of Repair Group 69) includesthe further
RepairGroupsbelongingto GroupO.
*3
The two folders with Group 1 are to be regarded as one folder; i.e. file the "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group1 -Engine, part I" (up to
Repair Group 13).
*4
Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe furtherRepair
Groupsbelongingto Group1.
Foreword
Printed in Germany -34, October 1999 VORW.CHP

Foreword Boxster
*5
The two folders with Group 9 are to be regarded as one folder; i.e. file the 'Technical Information"
notices only in front of the repair descriptions in the folder "Group9 -Circuit diagrams, part I" (up to
the '99 model).
*6
The second folder "Group9 -Circuit diagrams, part 2" (as of the '00 model) includesthe further
circuit diagrams belongingto Group 9.
The"Boxster"TechnicalManualhasthe samestructurein eachfolder,with the followingbreakdownfor

all Groups:
Title page, "Boxster" Technical Manual

> Foreword
Title page: "Technical Information"

> Table of Contents,Technicalinformation
> Technical information
Title page: "Repair"

> Repair Groups: overview
> Table of Contents,repairs
> General/technical data
> Instructions on repairs
As can be seen from the breakdown,the publishedTechnical Informationis in the front part of each
folder -numbered according to the Groups. The Table of Contentsassigned to each Group will be
periodicallyupdated.
Followingthe Technical Information,separated by a title page, the instructions on repairs -assigned

according to the Groups or broken down into Repair Groups -are included in the folder.
Theinstructionson repairswill be extendedand updatedby meansof supplements.
Note
Sheets that already exist in the "Boxster"TechnicalManualand are updated or revised and thereby
exchanged by a supplementare designated "Replacementsheet". Revisionsor technical modificationson
pages of these replacementsheets are identified for the user with a vertical bar at the margin.
Foreword
VORW.CHP Printed in Germany -34, October 1999

Boxster Overview of repair groups
Group 0: Entire vehicle -General 0

Maintenance 03
Group 0: Diagnosis 0
Sales check 01
On-boarddiagnosis 03
DMEdiagnosis 24
Tiptronic diagnosis 37
ABS diagnosis 45
Group 0: Diagnosis 0
Airbag diagnosis 69
Seat memory diagnosis 72
Heatingdiagnosis 80
Alarm system diagnosis 90
PCMdiagnosis 91
ParkAssistentdiagnosis 91
HBAdiagnosis 94
Group 1: Engine 1
Engine-Crankcase, suspension 10
Engine-Crankshaft, pistons 13
Group 1: Engine 1
Engine-Cylinder head,valve drive 15
Engine-Lubrication 17
Engine-Cooling 19
Group 2: Fuel, exhaust, engine electronics 2

Fuel supply, control 20
Exhaustsystem, turbocharging 21
Fuel system, electronic injection 24
Fuel system, K-Jetronic 25
Exhaustsystem 26
Starter, power supply, cruise control 27
Ignition system 28
Group 3: Transmission, manual transmission 3

Clutch, control 30
Manual transmission -Actuation, housing 34
Manual transmission -Gears, shafts, into gearsh 35
Final drive, differential, differential lock 39
Group 3: Transmission, automatic transmission 3

Torque converter 32
Automatic transmission-Actuation, housing 37
Automatic transmission-Gears, control 38
Final drive, differential,differential lock 39
Overview of repair groups

Printed in Germany -34, October 1999 REPGRU.CHP

Group 4: Running gear 4

Front wheel suspension, drive shafts 40
Rear wheel suspension, drive shafts 42
Wheels, tires, suspension alignment 44
Anti-Lock Brake System (ABS) 45
Brakes -Brake mechanics 46
Brakes -Hydraulics, regulator, booster 47
Steering 48
Group 5: Body 5
Bodyfront 50
Bodycenter,roof, frame 51
Bodyrear 53
Lids,flaps 55
Door front,centrallockingsystem 57
Group 6: Body equipment, exterior 6

Slidingroof 60
Convertible
top, hardtop 61
Bumpers 63
Glazing,windowcontrol 64
Exteriorequipment 66
Interiorequipment 68
Passengerprotection 69
Group 7: Body equipment, interior 7
Linings,insulation 70
Seatframes 72
Seatupholsteries,covers 74
Group 8: Air conditioning 8

Heating 80
Ventilation 85
Air conditioning 87
Auxiliaryair conditioningsystem 88
Group 9 Electrics 9
Instruments,
alarmsystem 90
Radio,telephone,on-boardcomputer,navigation 91
Windshieldwiperandwashersystem 92
Lights,lamps,switchesexterior 94
Lights,lamps,switchesinterior,theftprotection 96
Group 9: Circuit diagrams 9

Wiring (up to and includingthe '99 model) 97
Group 9: Circuit diagrams 9

Wiring(fromthe '00 model) 97
Overview of repair groups

REPGRU.CHP Printed in Germany -34, October 1999

Boxster Contents
3 Transmission, manual transmission
3 Power transmission
3 Technicaldata (transmissionG 86) 3 1
30 Clutch, control
30 50 37 Disassembling
Bleeding
Removing
Clutch boosttheand clutch
spring:
installing
and assembling
system.
allocation
clutch pedal.
and
clutch. grease specification 30. 1
30 01 07 30- 5
3005 19 30. 7
30 30- 15
8
34 Manual transmission -Actuation, housing
34 01 55 Adjusting
Changing
Removing
Disassembling intermediate
and and checking
installing
and assembling
assembling lever transmission
theshift
transmission shift
(transmission
and transmission console.
selector oilG 86 (transmission cables.
connection) G
case 86 cover G 86) 34- , 1
34 08 19 34- 2a
34 12 19 34- 2e
34 33 15 34- .2m
34 35 19 34- 3
34 35 37 34- .11
34 55 37
(transmission
Disassembling G and 86) assembling transmission case (transmission G 86) 34-19
343737 34 -25
35 Manual transmission -Gears, shafts, into gearsh.
35 40 37 Disassembling and assembling the input shaft (transmission G 86) 35 -1

35 40 15 Adjusting
Disassembling
the input
and shaft
assembling
(transmission
output shaft
G 86) (transmission G 86) . 35 -9
35 59 37 35-11
39 Final drive -Differential, differential lock
39 0919 Removing
Disassembling and installing
and assembling
differential the (transmission
differential (transmission
G 86) G 86) 39 -1
39 0937 39 -5
39 0815 Adjusting the drive set (transmission G 86) 39-11
3 Transmission, manual transmission 1

Printed in Germany -24, 1998 986TOC
Boxster Transmission 3
3 Technical data (transmission G 86)
5-speed manual transmission G 86
-
~
'-Y
34350001
Type Code letter Equipment Installed in Model year
G 86/00 CWA 5-speed Boxster 97/98

G 86/00 OW 5-speed Boxster 99
G 86/01 EFO 5-speed Boxster 00
3 Technical data (transmission G 86) 3 -1
1 Printed in Germany -30, 1999 9863_1

3 Transmission Boxster
Technical data (transmission G 86)
Identification of the transmission G 86
171~96
Identification and construction date of the

transmission:
Example: CWA 14 07 6
CWA = Code letter

14 = Day
07 = Month (July)
6 = Year (1996) of manufacture
. 3-2
9863_1
3 Technical

data (transmission
Printed in Germany -30,
G 86)
1999
Boxster Transmission
1 st gear 8 -Transmission case cover
2 -2nd gear 9 -Input shaft
3 -3rd gear 10 -Output shaft
4 -4th gear 11 -Ball bearing
5 -5th gear 12 -Differential
6 -Reverse gear 13 -Tapered roller bearing
7 -Transmission housing 14 -Tapered roller bearing
3 Technical data (transmission G 86) 3-3

Printed in Germany, 1996 9863_1

Technical data (transmission G 86/00/01J
Manual transmission

Printed in Germany -30, 1999 9863_1

Tightening torques
Screw plug, oil drainage

and oil filling M24 25 (18)
Guide sleeve for release

bearing on transmissionhousing M8 35 (26)
Retaining
plate,reversinglight
switchon transmissionhousing M8 25 (18)
Plug, reversing light switch

on transmissionhousing M8 10 (7)
Transmissioncasecoveron
transmissionhousing M8 25 (18)
Switchinterlockon
transmissionhousing M8 25 (18)
Screwsfor relayshaft M22 40 (29)

Torx screwfor
reverseidler shaft M8 35 (26)
Coverfor interiorshiftrod
Interlock (5th and reverse gears)

Balljournalfor releaselever
on transmission housing M8 25 (I8)
Coverfor finaldrive
Crown wheel on differential

housing MID 60 (45) + 450 rotary angle

Printed in Germany. 1996 QRR~ 1

Transmission Boxster
Bracketfor shiftcableson
transmissionhousing MID 45 (33)
Rockerholderon
transmission
housing M8 23 (17)
Gearshiftleveron
interiorshiftrod M6 23 (17)
Transmission MI2 85 (63)

on engine MID 45 (33)
Transmissionsupporton
transmissionhousing MID 65 (48)
Hydraulic mount on
support side part M8 25 (18)
Driveshafton
transmission
flange M8 39 (29)
Clutchslavecylinderon
transmission M8 23 (17)
3-8 3 Technical data (transmission G 86)

9863_1 Printed in Germany, 1996

Clutch, control Boxster
Disassembling and assembling clutch
8
I
6
I
~
0 ~ 0
n
'1)
~
0
0
~
[/
r 0
~
0
,t1) 0
~ 0
~
~~;ii)
I!
!
~--- .I
.-~~~
.
L-. -~
I
1 ~O
I (
2 ~ ~o\ J
I .~o I
] ~/
0
~
11 I I
3 4 5
30 -2 30 50 37 Disassembling and assembling clutch

986301 Printed in Germany, 1996
J
~
Boxster Clutch, control
Note:
No. Designation Qty. Removal Installation
Releaselever 1
2 Releasebearing 1 Do not wash out bear-
ings. Replace noisy bear-
ings. Do not grease slid-
ing surface of release
bearing or guide tube
3 Retainerspring
Note
4 Cylinder-head 6
bolt The bolts always must be tightened and loosend in
several steps and crosswise in order to prevent
deformation of the thrust-plate housing
5 Thrust plate
6 Driveplate 1 Centre with mandrel, VW

special tool 3176
7 Pan-head
screw 8 Initialtorque 25 Nm
MIO x I x 50 (18 ftl b.)
Finaltorque 900
8 Double-mass 1 Ensurethe centring pin is

flywheel seated firmly
9 Needlebush
30 50 37 Disassembling and assembling clutch 30 -3

Printed in Germany, 1996 986301

1
Boxster Clutch, corltrol
30 01 07 Bleeding the clutch system
Important notes Filling/bleeding
Theclutchhydraulicsmustalwaysbe filledor 1. Fillthe fluid reservoirup to the upperedge

bledusinga pressurefillingandbleedingdevice. with newbrakefluid.
Furthermore, the bleedervalvemustbe opened Connect bleeding device to the fluid
sufficientlyandthe gaugepressuremustbe ap- reservoir.
prox. 1.5 bar.
Before the system is filled or bled, the clutch Note

pedal must be in the "pedal fully depressed" U~ie only new DOT 4 brake fluid.
position.
Thisbrakefluid is availableunderthe following
Important: As there is no system pressure, part number:
servo kinematiceffects will cause the clutch Containerquantity 1 litre = 000.043.203.66
pedal to move forward abruptly. In order to Containerquantity30 litres = 000.043.203.67
avoid damageI the pedal must be guided
manually.
Bleed the system until no more bubbles appear

at the bleeder valve (use a collecting bottle with
transparent hose).
If the system was open previously(e,g. for com-

ponent replacement),the minimum filling or
bleeding time must be 30 seconds.
682 -96
2. Movepedalto the fullydepressedposition.

Whendoingso, guidethe pedalby handso
that it does notmoveforwardabruptly.
3. Switchon the bleedingdevice.Bleedingpress-

ure approx.1.5 bar.
30 01 07 Bleeding the clutch system 30 -5

Printed in Germany -5, 1996 986305

Clutch, control Boxster
4. The bleeder valve on the clutch slave cylinder 5. Switchoff and disconnect the bleedingdevice.
must be opened until clear, bubble-freebrake Correctthe brakefluid levelif necessary.
fluid emerges.
Use a collecting bottle for precise examination
of the emerging brake fluid for cleanlinessand
freedom from bubbles.
'-
~
>1Jr
189 -96
690/1 -96
Note
If the system was open previously(e.g. for com-
ponent replacement),the minimumfilling or
bleedingtime must be 30 seconds.
30 -6 30 01 07 Bleeding the clutch system

986305 Printed in Germany. 5, 1996

""
~
Boxster Clutch, actuation
30 05 19 Removing and installing the clutch pedal
Important notes Pedal-group versions (distinction)

The description below appliesto left-handdrive 1. The pedals of Boxster vehicles as of
vehicles. Mod. '98 (as of Mod. W) are identical to
On right-handdrive vehicles,the clutch pedal the 996 pedals,with the exception of the
lever is located directly next to the brake boost spring and boost-springbracket.
pedal (separated by the steering outer tube
in the case of left-handdrive vehicles). 2. The Boxster pedals before Mod. '98
Assembly/disassemblyfor right-handdrive (before Mod. W) differ from the pedals
vehicles is similar to the procedure for as of Mod. '98 in the following respects:
left-handdrive vehicles.
Bracket for clutch boost spring cannotbe
Before the start of disassemblywork on the unscrewed. Consequently,the boost-spring
pedals,the clutch boost spring must be fixed bracket cannotand need not be adjusted.
with a cotter pin (arrow at No.5). Furthermore,the distancebetweenthe bearing
Important: secure the cotter pin (bend it over). pins of the boost spring is 3 mm less.
Pedal bearing axle with differentfastening

method >arrows< (clamping of the
steering outer tube and fixing of the
pedal-bearingaxle)
No return spring on the brake pedal
465_98
32_1_98
BoxsterpedalsbeforeMod.'98
30 05 19 Removing and installing the clutch pedal 30-7


Removing and installing the clutch pedal
~---
~~@
~
':::- \\\
6x "'..""'. ...
'.
.:.' ~ .
4 .5a :
~
5b / ~
r:;;5)
/ (Ql) ~ ~
~
..'
.'
...:
'. ..
' 5a
"..., '.
(Ql) j
."
5 :
3_c:s;::'>~" ..~~: i
2
? ~
~ 1 :
465_98
A = Clutch pedal area

B = Brake pedal area
. 30 -8 30 05 19 Removing and installing the clutch pedal

986307 Printed in Germany -24, 1998

~"
\\\
A = Clutch pedal area
Note:
Switch 1 Releaseby turning 90°, Before installation,pull

and pull out of the operating plunger out of
installationopening the switchasfar as it will go
2 Retainingclip 1 Replace if necessary
3 Pin 1
4 Clamp 1 Replace
5 Boost spring with bracket
(bracket cannot be
removed before Mod. '98)
1 Secure boost spring with Installthe assembly
cotter pin (arrow at No.5) consisting of bracket,
Insertthe cotter pin (0'3 mm) boost spring and clutch
intothe assemblybore and pedal lever.
bendover ends. Observeproper allocation
Thenundothe threefastening when replacingthe boost
spring.* *
nuts of the bracket(arrows)
and removethe boostspring Observe assemblyand
togetherwith bracketand adjustmentspecification
clutchpedallever (No.6) for the bracket (assembly
instructions under
Installation,step 3)
5a Boost spring bearing 2 Replace if necessary.
Alwaysobserve note with
regard to greasing* *
5b Pin 1 Always observe note with
regard to greasing**
6 Clutch pedal lever 1 Removetogetherwith boost
spring No.5 and bracket
6X Bushings 2 Remainin the clutch pedal Check,replace if
lever necessary.
Lubricate. Use grease
specified*
Lubricate the bushings of the clutch and brake pedals (6X and 14X)with "Optimol, Optitemp LG 2"
grease, part No.: 000.043.203.37 (deliveryquantity: 80 g tube).
* Information can be found in RepairGroup 30 -Servo No. 30 Clutch boost spring: allocationand
grease specification. In the case where lubricatingthe boost spring bearing surfaces is not
permissible,the assemblyinstructions under Installation,steps 2.1 and 2.2 can also be followed.
3005 19 Removing and installing the clutch pedal 30 -9


1
Clutch, actuation Boxster
Notes on removal and installation
Removal
Warning 4. Detachdiagnosticsocket.
& Danger of injury and damage

during disassembly and assem-
bly work!
Clutch boost spring can
disassemble automatically!
Before the start of disassembly

work in the area of the clutch
pedal lever (exception:clutch
pedal switch),the clutch boost
spring must be fixed with a
cotter pin (Fig. 478_98).
1. Disconnectbatterygroundcable.
2. Removedriver'sseat(to facilitatework).
3. Removeair duct (A). 5. Detach relaycarrier, unclip and lower into the
The air duct is plugged in, footwell.
86_98
6. Releaseclutch pedal switch by turning it 900

and pull it out of the installationopening.
290_1_97
30 -10 30 05 19 Removing and installing the clutch pedal

986307 Printed in Germany. 24, 1998

7. There is an assemblybore in the guide rod 10. Undo fastening nuts from boost spring
for the clutch boost spring. Insert a 3 mm ~ bracket (arrows).
cotter pin in this bore, and bend over the Requirement: Boost spring secured with
ends (securing: refer to Fig. 478_98). a cotter pin.
Removeclutch pedal lever together with
8. Removepin between the clutch push rod and boost spring and bracket. The bracket is not
clutch pedal lever. removableon the Boxster before Mod. '98.
9. Removeretainer (1) on the pedal bearing axle.
478_98
Installation
1. Inspect all bearing bushings X for clutch pedal
lever and replace them if necessary. Lubricate
sliding surfaces of the bearing bushingsX
(Fig. 466_98) and the pedal bearing axle
with Optimal, Optitemp LG 2,
part No. 000.043.203.37.
2. Assembleboostspring,bracketandclutch
A -Clutch pedal lever 466_98 pedallever.
B -Brake pedal
C -Steering outer tube
Descriptionin 2.1 or 2.2.
X -Bearing bushings 2.1 BoxsterMod. '98/ partlyMod.'99
2.2 Boxsterfrom currentMod.'99
1 -Retainer
Note
Differenttypes of boost springs can be fitted
in the Boxster.
Observeproper allocationwhen replacingthe
boost spring and/or the bracket.
3005 19 Removing and installing the clutch pedal 30-11

Printed in Germany -24. 1998 986307

In some cases, a modified (optimised)clutch 2.2 Boxsterfrom currentMod.'99

pedal must also be used when replacing the
boost spring. Identification/distinction:
Push rod closed / boost spring components
Lubricatingthe boost spring bearing surfaces is coated.
sometimes necessaryand sometimes prohibited The date of introductionfor this boost spring
(according to boost spring version), is containedin the Parts Catalogue.
Informationcan be found in the Technical Ma- Engagethe hexagon-socketbolts of the boost

nual- RepairGroup 30, ServoNo. 30 Clutch spring into the hexagonon the clutch pedal
boost spring: allocation and grease specification. (arrow).
2.1 BoxsterMod.'98/ partlyMod.'99 Important: Do not lubricate since the sliding

surfaces of this boost spring version are coated.
Identificationl distinction: 'Do not lubricate' applies to all sliding surfaces
Boost-springpush rod open on one side, boost (boost spring pins, boost spring bearing in the
spring components not coated. bracket, bearing pins on the boost spring, and
the boost spring in the boost spring pot).
Grease pin for boost spring (arrow) with mating
bearing on the boost spring push rod, the boost
spring bearing (arrows)and the bearing pins on
the boost spring with Optimol, Optitemp LG 2;
part No. 000.043.203.37.
First remove old grease with solventnaphtha.
~
""'
/
'- Do not lubricate (prohibited) 467_98
Note
Silver bracket (986.423.571.00) and boost
spring with white marking (986.423.081.08
Lubricationnecessary (arrows) 31_1_98 Mod. '98/ partly Mod. '99 or 986.423.081.11
from current Mod. '99) must be used only in this
combinationand installed only in the Boxster.
30 -12 30 05 19 Removing and installing the clutch pedal


3. Installationand adjustmentspecificationfor
boost spring bracket.
Install preassembled boost spring bracket
with clutch pedal lever.
Not valid for Boxster vehicles before Mod. '98
(bracket cannot be unscrewedor adjusted).
\
To do this: \
~)
4. 1.+5.
Step 1:
Tighten the three fastening nuts (arrows) only
2. \I~
slightly (the bracket must still be movable),
Step 2:
Tighten the clutch master cylinder to 10 Nm
(7.5 ftlb.) (if the clutch master cylinder was
32_98
detached).
Step3: Note
Press the clutch pedal againstthe direction of The push rod of the clutch save cylinder should
travel until the pull stop in the clutch master not be lubricated in general (for all versions).
cylinder is reached.
4. Fit new retainer on the pedal bearing axle.
Step 4: On vehicles as of Mod. '98, subsequently
Removecotter pin (retaining pin) on the spring secure the retainer by wedging it with a
cup so that the clutch pedal is pressed against mandrel.
the rubber stop in the boost spring bracket.
5. Install clutch pedal switch.
Step 5: First pull operating plunger out of the switch
The bracket is screwed down with the clutch as far as it will go.
pedal pressed back (to make full use of the By means of its self-adjustmentfunction,the
slots). Tighten hexagon nuts (arrows)in the switch then compensatesfor tolerances in
prescribed sequence.Tighteningtorque: the pedals.
7.5 Nm (5.5 ftlb.),
Sequence: Sa / Sb / Sc
30 05 19 Removing and installing the clutch pedal 30 -13
.
~-::::?'
6. Checkthe interlockswitchadjustment
on
vehicleswith interlock.
Adjustment specification for interlock switch:
The switch must be aligned so that, with

the clutch pedal depressed, it is operated
approx. 1 to max. 2 mm before the limit stop
of the clutch slave cylinder is reached.
49_98
7. Installrelaycarrier,diagnosticsocketandair
duct.
8. Performa functiontest on clutchandbrake

operation.
30 -14 30 05 19 F~emoving and installing the clutch pedal


30 Clutch boost spring: allocation and grease specification
1. Boost spring bracket allocation 2. Standard boost spring allocation
1.1 Boxster before Mod. '98 2.1 Boxster up to Mod. '98

(boost spring bracket cannot be unscrewed)
The bracket for the boost spring cannot be
unscrewed. Boost spring No.1. Dimension X approx. 39
mm. Boost-spring push rod open on one side.
1.2 Boxster as of Mod. '98 Observe replacement procedure and grease
specification.
Silverbracket(986.423.571.00)and boost
springwith white marking(986.423.081.08or 2.2 Boxster Mod. '98 partly Mod. '99
(boost spring bracket can be unscrewed)
986.423.081.11/ see boostspringallocation)
mustbe used onlyin this combination
and Boost spring No.2. Dimension X approx. 42
installedonlyin the Boxster. mm. Boost-spring push rod open on one side.
Boost spring with white marking. Observe
Note replacement procedure and grease specification.
The gold-coloured bracket (996.423.571.00)

2.3 Boxster from current Mod. '99
and boost spring with purple marking (boost spring bracket can be unscrewed)
(996.423.081.09 or 996.423.081.11) are
Boost spring No.3. Boost-spring push rod of
assigned to the 911 Carrera (996) and must
closed. Boost spring with white marking.
not be installed in the Boxster.
Observe grease specification (do not lubricate
boost spring).
~"'r~ ~
31_98
* Distinction(ldentification
469_98
30 Clutch boost spring: allocation and grease spe(:ification 30 -15


3. Boost spring: The boost spring No.3 986.423.081.11 will be

Replacementprocedure used as a replacement (closed push rod / boost
spring painted white).
3.1 Boxster before Mod. '98 This boost spring should not be lubricated.
(boost spring bracket cannot be unscrewed)
The standard boost spring Nr.l (Fig. 469_98)
Spare Part No. 986.423.081.07 is no longer
availableafter existing suppliesare used up.
The boost spring 986.423.081.12 will be used
as a replacement.This boost spring has a clo-
sed push rod and should not be lubricated.
Identifyingfeature: All-roundgreen ring on the
boost spring housing (arrow).
The bolt 999.423.315.06 and the fuse
999.166.075.02 for connectionto the previous
clutch pedal are included in the scope of deli-
very of the boost spring.
469_98
'-:I::::f Whenthe boost spring No.3 is installed for the
;JJ first time, the optimised clutch pedal

996.423.139.09 must also be used.
47O_98
'"'"
,',
3.2 Boxster Mod. '98 partly Mod. '99
The standard boost spring No.2 (push rod on

boost spring is open on one side) Spare Part ~
No. 986.423.081.08 is no longer available
after existing supplies are used up.
~v
467_98
30 -16 30 Clutch boost sprirlg: allocation and grease specification

986307 Printed in Gem1any -24, 1998

Note 4. Greasespecification
The hexagon bolt 999.423.315.06 and the
fuse 999.166.022.02 for connectionto the It is essentialto observe the following
optimised clutch pedal are included in the grease specificationduring assembly
scope of delivery of the boost spring. work on the pedals.
This corresponds to the same scope as for
4.1 Pedal bearing axle
the boost spring version No.3 (from current
Mod. '99). Lubricationrequired in most cases.
Greasethe bearing bushings marked X and the
pedal bearing axle with Optimal, Optitemp LG 2,
Part No. 000.043.203.37.
3.3 Boxster from current Mod. '99

The boost spring No.3 (Fig. 469_98) is used

as standard and in the event of replacement.
A -Clutch pedal lever 466_98

B -Brake pedal
C -Steering outer tube
X -Bearing bushings
1 -Retainer
30 Clutch boost spring: allocation and grease specification 30 -17


4.2 Push rod of clutch master cylinder 4.3.2 Boxster Mod. '98 partly Mod. '99
Do not grease, as this could cause damage.
A. Standard boost spring:
Push rod open on one side. Componentnot
coated.
4.3 Spring boost area Grease pin for boost spring (arrow)with mating
Lubricationmay be required or prohibited, bearing on the boost spring push rod, the boost
according to the spring boost version. spring bearing (arrows)and the bearing pins on
In general,the following applies: Do not grease the boost spring with Optimol, Optitemp LG 2,
coated components,as this erodes the coating. part No. 000.043.203.37.
First remove old grease with solventnaphtha.
4.3.1 Boxster up to Mod. '98
(boost spring bracket cannot be unscrewed) The boost spring and the boost spring housing
A. Standard boost spring: are greased with a special grease on the inside.
Push rod open on one side. Componentnot This grease is not availableas a spare part.
coated. Replacethe entire boost spring (with boost
spring housing)if necessary.
Grease pin for boost spring with mating bearing
on the boost spring push rod, the boost spring
bearing and the bearing pins on the boost
spring with Optimol, Optitemp LG 2, part
No. 000.043.203.37.
First remove old grease with solvent naphtha. ""
B. Spare part replacement boost spring ~

~
Spare part No. 986.423.081.12.
--~
Identifying feature: Closed push rod and an all-
round green ring on the boost spring housing.
Do not grease any areas as the components a
re coated.
31_1_98
B. Spare part replacement boost spring

Spare part No. 986.423.081.11 (versiQnas
from current Model '99/ Figure467_98).
Identifyingfeature: closed push rod and hexagon
nuts for connectionto the clutch pedal.
Do not grease any areas as the components

are coated.
30 -18 30 Clutch boost spring: allocation and grease specification


Boxster Clutch, actu;ation
4.3.3 Boxster from current Mod. '99

Push rod closed / connectionto clutch pedal

with a hexagonbolt.
Do not grease any areas as the components

are coated.
/ '.
.""\
467_98
30 Clutch boost spring: allocation and grease spe(:ification 30 -19


Boxster Manual transmission -Actuation, housing
34 01 55 Changing and checking transmission oil (transmission G 86)
Filling capacity: 2.25
Note
Use only transmission oil approved

by Porsche.
Refer to Parts Catalogue!
1. Removetransverse strut member.
2. Unscrewthe oil drain plug with a socket

wrench insert (Refer to Workshop EquipmentMa-
nual, Chapter 2.4, No. 33) and drain oil with the
vehicle horizontal.
3. Cleanthe drain and filler screw.
4. Fill in 2.25 I transmission oil with the vehicle

horizontal.
190-96
Note
At 2.25 I, the oil level is 11 mm belowthe filler 5. Tightenthe drain and filler screw with 25 Nm
opening. (18 ftlb.).
Use a bent wire hook (shop-made)to check
the level.
34 01 55 Changing and checking transmission oil (transmission G 86) 34 -1


34 08 19 Removing and installing shift con!iole
Tools
No. Designation Special tool Explanation
Lockingbridge 9619
34 08 19 Removing and installing shift console 34-2a

Printed in Germany -5, 1996 986342a

Manual transmission -Actuation, housing Boxster
Removing and installing shift console
Removal
1. Removecentre console (see Group68, Inte- 4. Disengagethe selector and shift cables on
rior equipment). the shift console. To do this, slide the locking
sleeveforward as far as it will go and turn it
2. Shifttransmissionto neutralandfix shiftlever clockwiseto removalposition.
withspecialtool 9619.
9619
==:=;;:
- -<-
-~
602-96
3. Removeshiftconsolecover.
1 -Selector cable (blue) 603-96
2 -Shift cable (black)
3 -Adjuster open
4 -Adjuster closed
5 -Support bracket
5. Disengagesupport bracket sleeves (5) on the

shift console. To do this, release the support
bracket sleevesand carefullypull out of the
support bracket.
6. Unscrewfasteningnutsfor the shiftconsole

andremovethe shiftconsole.
34 -2b 34 08 19 Removing and installing shift console

986342a Printed in Germany -5, 1996

~
Installation
Note
The shifting elementis designed so that installa-

tion and adjustmentare a single work step. 4 ..~
/
Preconditionsfor this are:
Special tool 9619 must be fitted to fix the

:,;
shift lever.
Thetransmissionmustbe in neutral. 'l

~
1. Install the shift console and tighten the fasten-
5
ing nuts with 10 Nm (7.5 ftlb.).
~ ..;..
~f/.J~2.]3 ~ ~
/5/ /,
_/ /
Note ./
The shiftandselectorcablesmustnot be ex- 1 -Selector cable (blue) 603/1 -96
cessivelybentor kinked. 2 -Shift cable (black)

3 -Adjuster open
4 -Adjuster closed
2. Fastenselectorand shiftcableson the shift 5 -Support bracket
console:
Fit support bracket sleeves (5) in the correct

position. It must be possibleto hear and feel 3. Removespecialtool 9619 and shiftthrough
them engage. all gearsas a test.
Engage shift and selector cables in the adjus- 4. Clipin shiftconsolecover

ters (3) without tension and close the adjus-
ters (see enlargedview). 5. Installcentreconsole.
3408 19 Removing and installing shift console 34 -2c


;\/~!
Boxster Manual transmission -AI~tuation, housing
34 12 19 Removing and installing shift and selector cables
Tools
459-97
Item Designation Special tool Explanation
A Removal tool Commerciallyavailable(refer to

Workshop EquipmentManual,
Chapter2.4, No. 21)
B Locking bridge 9619
34 12 19 Removing and installing shift and selector cables 34 -2e


Removing and installing shift and selector cables
...
...
.-'
/
'-" ~ :,
7
./
'"...
3
JlJ
t
3
~
595-96
1 -Selector cable (blue)
3 -Spacer nut
4 -Holder
5 -B+ wire
6 -Holder
34 -21 341219 Removing and installing shift and selector cables

986342a Printed in Germany. 13, 1997

'/
~
Removing and installing shift and selector cables
Removal
Note
The shift cable and selector cable can be 3. Disengageshift and selector cables on the
exchanged onlytogether, as they possess transmission.
a common locking piece. Until date of manufacture 21.4.97
1. Removecentre console (see Group 68,

Interior equipment).
2. Shift transmission to neutral and fix shift

lever with special tool 9619.
-
--.J
~
~
\.
1 -Selector cable (blue) 671-1-96

602-96
Note
The shift and selector cables must not be
excessivelybent or kinked.
Removecotter pins for retaining clips (A/BJ,

remove clips and pull shift and selector
cables off the ball head.
34 12 19 Removing and installing shift and selector cables 34 -2g


C-:
:::;.;.;-
Note
The transmission shift lever must be removed
so that retaining clip "A" can be removed.
To do this, remove retaining clip "G", unclip joint
rod at the top and unscrew securing screw "F",
Disengagesupport bracket sleeves"0" and

"E" on the support bracket. To do this,
release the support bracket sleeves (press
tabs in the direction indicated by the arrow)
and carefully pull out of the support bracket.
4. Disengage shift cables on the transmission, 414-97
As from date of manufacture 22.4.97

6. Lift shift console cover up and off.
Use commerciallyavailableremoval tool
(refer to Workshop EquipmentManual, 7. Disengageshift and selector cables on the
Chapter2.4, No. 21) shift cor]sole. To do this, slide the locking
sleeveforward as far as it will go and turn it
clockwiseto removalposition.
4 ~~
~
,...'
/
#.
',/'/i
1 ~
(
482-97
5. Removerear wall cover.
:::22

3 -Adjuster open
4 -Adjuster closed
5 -Support bracket
34 -2h 34 12 19 Removing and installing shift and selector cables

~
~
Boxster Manual transmission -Actuation, ass. housing
8. Disengagesupport bracket sleeves (5) on the The transmission must be in neutral,

shift console. To do this, release the support
bracket sleeves and carefullypull out of the
support bracket.
Note
9. Relieveparking brake cable, unscrew
Shift and selector cables must not be excessi-
fastening nuts for parking brake lever support,
vely bent or kinked.
and lift the support only far enoughso that the
selector cable can be removed from the side.
1. Guide shift and selector cables from the
passengercompartment, through the rear wall
10. Removelocking piece from the rear wall and
and to the transmission.
take out shift and selector cables. Take care
not to soil the passenger compartment. Note
Alwaysmake sure that the B+ wire is routed
between the shift and selector cables (A).
--
AI \.
/ ~
B-.=::::::;:
-AI \
\\~ ,p1~:;;;'
..~.+::
'::'~\":,:~'!""I;(
'\i
604_96
."/i
,\
\\\
\\\ ~~~:\!;!
A -Shift and selector cables 604_96
B -B+ wire
Installation
The shift and selector cables are designed so
that installationand adjustmentare a single
work step.
Preconditions
for this are
Special tool 9619 must be fitted to fix the

shift lever.
34 12 19 Removing and installing shift and selector cables 34 -2i

--
,.,-
Manual transmission -Actuation, ass. housing Boxster
2. Fasten shift and selector cables on the

transmission.The end pieces and support
brackets of the shift and selector cables must
be heard and felt to engage and, on the
version with tab washer, the cotter-pin heads
on the retaining clip "A" musf face down.
Note
Alwaysreplace micro-encapsulatedsecuring
screw "F"and tighten to 23 Nm (17 ftlb.).
604_96
4. Routethe shift and selector cables and B+

wire correctly, and fasten the parking brake
lever support. Tighteningtorque of the
fastening nuts: 10 Nm (7.5 ftlb.).
:-~,
;f&
~
~
671-1-96
2
3. Insert locking piece in the rear wall and fit y" I

rear wall cover. 6 5

3 -Spacer nut
4 -Holder
5 -B+ cable
6 -Holder
34 -2j 341219 Removing and installing shift and selector cables


Note 8. Adjust parking brake and install centre

Correct routing of the shift and selector cables console.
is a prerequisite for precise shifting.
5. Fasten shift and selector cables on the shift

console:
Fit support bracket sleeves (5) in the correct

position. It must be possible to hear and feel
them engage.
Engage shift and selector cables in the

adjusters (3) without tension and close the
adjusters (see enlarged view),
~
i.::.j~
~
5 ..,/
~/
\/
:;/
:::22
1 -Selector cable (blue) 603-1-96
3 -Adjuster (open)
4 -Adjuster (closed)
5 -Support bracket
6. Removespecial tool 9619 and shift through

all gears as a test.
7. Clipin shiftconsolecover
34 12 19 Removing and installing shift and selector cables 34 -2k


"':;:-~
~
34 33 15 Adjusting intermediate lever (transmission connection)
Tools
~ > - S~p~~;:=:
A177USA
y..
c
477-97
IIB11 Designation Special tool Explanation
A Removaltool Commerciallyavailable
(refer to Technical Equipment
Manual,Chapter 2.4, No. 21)
B Threadedpiece VW771/15
c Hexagon-headbolt Commercially available;
M10x 110 make a 5mm wide and 3 mm
deep groove in the head.
34 33 15 Adjusting intermediate lever (transmission connection) 34 -2m

Printed in Germany -13, 1997 986342m

A~djusting intermediate lever {transmission (:onnectionJ
461-97
Transmission connection:
A -Relay shaft
B -Shift lever
C -Intermediate lever
D -Stop cap
E -Lock nut
F -Rubber washer (as of date
of manufacture 22.4.97)
~14 -2n 34 33 15 Adjustiing intermediate lever (transmission connection)

986342m Printed in Germany -13, 1997

Boxster Manual transmis!;ion -Actuation, ass. housing
Adjusting intermediate lever (transmis~jion connection)
Note
The intermediate lever is machine-caulkedas
standard after adjustment of the shift
mechanism.
If the transmission connection or parts of the
transmission connection are replaced during
repairs, the caulked intermediatelever must be
exchangedfor an adjustableintermediatelever
and readjusted.
A misadjustmentof the intermediatelever can

result in the following problems:
higher shifting friction.
1 st, 2nd, 5th or reverse gear cannotbe

engaged.
461-97
1. Move shift lever to neutral position and
disengage shift cables on the transmission. Transmission connection
Use a commerciallyavailableremovaltool for
this purpose (refer to Workshop Equipment A -Relay shaft
Manual,Chapter 2.4, No. 21) B -Shift lever
C -Intermediate lever
2. Disengageend piece of intermediatelever D -Stop cap
at shift lever "8", E -Lock nut
F -Rubber washer (as of date of manufacture
22.4.97)
34 33 15 Adjusting intermediate lever (transmission connection) 34 -20

Printed in Germany -16, 1997 986342m

3. Turn relay shaft "A"counterclockwiseto push 5. Adjustthe length of the intermediatelever by

it to the upper stop and fix it with a suitable means of the thread until the end piece can
weight (e.g. special tool 9350). be pressed onto the upper ball pin without
tension.
Note
The face sides of the intermediatelever end
pieces must be at right anglesto the centre
axis of the ball pins.
484-97
4. Turn shift lever .C. counterclockwiseto the

upper stop (shift gate 1/2) and fix with
shop-madetool.
478-97
6. Tighten lock nut.
7. Press shift cables onto the ball pins and

check shifting function.
A -Hexagon-head bolt 482-97

B -Threaded piece VW771/15
34 -2p 34 33 15 Adjusting intermediate lever (transmission connection)

986342m Printed in Germany -16, 1997

Note
Ball socket and ball pin versions with retaining
clips must be lubricated with a light coat of
Universallow-temperaturegrease.
Do not grease ball socket and ball pin
versions without retaining clips (as of date of
manufacture22.4.97).
34 33 15 Adjusting intermediate lever (transmission connection) 34 -2q

Printed in Germany Purchased
-13, 1997 from www.WorkshopManuals.co.uk
986342m
34 35 19 Removing and installing transmis~;ion G 86
Tools
233-96g
Item Designation Special tools Explanation
Supporting bridge lO-222A

2 Support feet 9591/1
34 35 19 Removing and installing transmission G 86, 34 -3


Removing and installing transmission G 86
Removal
1. Secure engine in installationposition on the 9. Unscrewthe clutch slave cylinder and hang
transport carrier with special tools 10 -222 A up at the side with the hose connected.
and 9591/1.
Note
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 in the vehicle!
10. Disengageshift and selector cables on the

transmission.
Until date of manufacture 21.4.97
194-96
2. Removethe diagonal braces and transverse

strut member.
3. Removestabilizerbar.
4. Removesilencer with catalytic converters (see

Group 10 -Removing and installing engine).
5. Removethe rear cross member (V-strut),
6. Unscrew mount for silencer on the transmissi-

on.
1 -Selector cable (blue)
Removedrive shafts at the transmissionand 2 -Shift cable (black)
protect the shafts against damage (use scrap
pieces of hose with a diameter of 30 mm). Note
The shift and selector cables must not be
8. Undo the plug connectionfor the reversing excessivelybent or kinked.
light switch.
34 35 19 RE~moving and installing transmission G 86

34 -4
986341 Printed in Gennany -13, 1997

Boxster Manual transmission -A,ctuation, housing
Removecotter pins for retaining clips (A/B), ""

/"
"""
pull off clips and pull shift and selector
cables off the ball head.
-f
/~
The transmission shift lever must be
removed before retaining clip "A" can be '--
removed. To do this, remove retainingclip -(
"G", unclip the joint rod at the top and

unscrew securing screw "F",
,,~
Disengage support bracket sleeves"0"
and "E" on the support bracket. To do this,
396-96
release the support bracket sleeves (press
tabs in the direction indicated by the arrow)
and carefully pull them out of the support 13. Remove transmission support with
bracket. hydraulic mounts on the left and
right-hand sides.
11. Disengage shift cables on the transmission.
As from date of manufacture 22.4.1997 Note
Fasteningnut "C" (M12) must not be undone.

Use commerciallyavailableremoval tool The transmissionprop will otherwise be
(refer to Workshop EquipmentManual,
damaged.
Chapter 2.4, No. 21).
"--"
I.,
AI
..\ c
-.-:::./""?~~~--
462-97 435-97
A = Transmissionsupport
B = Hydraulicmount
12. Place a transmissionjack underneaththe C = M12 Fasteningnut
transmission and secure the retaining strap,
34 35 19 Removing and installing transmission G 86 34 -5


--
'\.J-
I~
1
14. Unscrewthe fastening screws betweenthe

transmission and engine.
Use a polygon wrench (10 mm,
part No. 999.571.052.02) for screw No.5.
193-96
A = Washer
193-96
15. Pull the transmission to the rear and lower it

carefully.
Installation
Installation is performed in reverse order, taking
the following points into account.
1. Clean teeth of the drive shaft and grease with

a thin coat of Olista Longtime 3 EP
(availableas spare part).
2. Make sure that the dowel sleevesare properly

seated in the crankcase. Hexagonnut
Multiple-toothnut
3. Carefullyslide in the transmission,and
properly secure it to the engine.
4. Fit the clutch slave cylinder and tighten
fastening screw to 23 Nm (17 ftlb.).
34 -6 34 35 19 Removing and installing transmission G 86


Note Tightening torques (transmission G 86):

If the piston rod cannot be pushed back
manuallywhen the clutch slave cylinder is fitted, Diagonalbrace to carrier
the bleeder valve must be opened. side member and
body (MID) = 65 Nm (48 ftlb.)
Connecta collection bottle with hose for this
purpose.
Rear cross member
5. Bleed the clutch system, (V-strut)to transverse
strut member and
body (MID) 65 Nm (48 ftlb.)
Stabilizer bar to carrier side

member (M8) = 23 Nm (17 ftlb.
Stabilizer mount to
stabilizer bar (M1 0) 46 Nm (34 ftlb
Drive shaft to trans-

mission flange (M8) = 39 Nm (29 ftlb.)
Transmissionprop to
transmission (MID) = 65 Nm (48 ftlb.)
Hydraulic mountsto carrier

side part (M8) = 23 Nm (17 ftlb.)
Clutch slave cylinder

to transmission (M8) 23 Nm (17 ftlb.)
Gearshiftlever on interior
shift rod (M8)* = 23 Nm (17 ftlb.
* Note
Always replace micro-encapsulated screw.
34 35 19 Removing and installing transmission G 86 34 -7


34 35 37 Disassembling and assemhling transmission G 86
Tools
3
2

1 Pullerwith V.A.G.1582
grip V.A.G.1582/2
2 Press-infixture 3235
3 Driver sleeve VW192
4 Hook VW681
34 35 37 Disassembling and assembling transmission G 86 34 -11


Disassembling and assembling transmission G ~~6
25 22
I
~~~~~;~~~~~
18 -~ @'i!-- ~
19 /F,'l
24
17
16
21 """
20 ~ '26
/~~ 4-
c1:J:
27
23

Purchased
Printed in Germany, 1996 from www.WorkshopManuals.co.uk
9863411
"
Note
If the 5th and reverse gears stick or catch after adjustmentof the gear changing mechanism,before re-
moving and disassemblingthe transmissionfirst remove the lock for the 5th and reverse gears, inspect it
and, if necessary,replace it (see Page 34 -32)
Note:
Torx screw 2 Always replace,

tightening torque 35 Nm
26 ftlb.)
2 Guidesleeve 1
3 Toroidalsealingring 1 Always replace
4 Shaftseal 1 Removewith special tool Lightly coat the sealing

VW681 lip with multi-purpose
grease and drive it in as
far as it will go using the
special tool VW 192
5 Cuplspring 1 Small diameter (curved

side)to the guide sleeve
6 Snap ring 1 Note the thicknessfor re-

fitting (must not be mixed
up). If ball bearings
No.7, the input shaft or
the transmissionhousing
are replaced,the thick-
ness must be remeasured
(see Page 35 -9).
7 Ballbearing 1 Removewith specialtools Press in with special tool

V.A.G.1581 andV.A.G. 3225. The open side of
1582/2 the plastic retainer faces
the guide sleeve
8 Snapring 1 As for No.6
9 Hexagon-head
bolt 1 Tighteningtorque 25 Nm
(18 ftlb.)
10 Tab washer
11 Reversinglight switch 1 Insert in correct position
34 -14 34 35 37 Disassembling and assembling transmission G 86


Note:
12 Toroidalsealingring 1 Always replace and lightly

grease
13 Torx screw 1 Tightening torque 10 Nm
(7 ftlb.)
14 Torx screw Tightening torque 25 Nm

(18 ftlb.)
15 Transmissioncase cover 1, Seal with Loctite 574

(29 ftlb.)
17 Spacer 1
(29 ftlb.)
19 Spacer
20 Torx screw with collar 1 Tightening torque 25 Nm

(18 ftlb.)
21 Switch interlock 1
22 Input shaft
23 Output shaft
24 Relayshaft 1
25 Shift rod and shift fork, 3rd
and 4th gears
26 Interior shift rod 1
27 Shift rod with shift fork for 1 Replacethe shift rod for
1 st / 2nd / 5th and 5th and reverse gears
reversegears only as a complete
assemblywith shift
fork and driver


Instructions for disassembly and assembly
Disassembly 3. Pull the ball bearing for the input shaft out of
the transmission housing using the special
Note tools V.A.G. 1582 and V.A.G. 1582/2.
The differential does not have to be removed

in order to take out the gear set. Removalis
necessary only in order to determine which
deviation "r" is given on the crown wheel.
This deviation is necessary if the transmission
housingor tapered roller bearing for the output
shaft is replaced.
1. Clamp the transmission in the assembly

support using the special tool 9589 or
~ 540 and drain off the gear oil.
43-96
A = Puller with grip
4. Take out the input shaft "A", the output shaft

"B", the relay shaft "G", the shift rods "D" and
the shift forks "E" together.
,
c
E
42-96
2. Pull the clutch release lever off the ball journal

and remove with the release bearing.
..
44-96

9863411 Printed in Germany -13,1997

-E
Boxster Manual trar,smission -Alctuation, housing
Assembly
1. Assemblethe input and output shafts with the
shift rods and install them together in the trans-
~-$/
mission housing. I ~I
46 -96
3. Installthe switchinterlock.
Pushthe locking slide to the center position

and ensure that no gear is engaged.
45 -96
Insertthe switchinterlock.
2. Insertthe relayshaftandthe interiorshiftrod, Guidethe relayshaftintothe switchinterlock.
Engage3rd gear. Tightenthe switchinterlockwith the stipu-

latedtighteningtorque.
Insertthe relayshaft.
4. Insertthe bolts for the relay shaft and tighten
Positionthe interior shift rod next to the
them with the stipulated tighteningtorque.
guide hole of the bearing cover, push the
shift finger into the driver of the relay shaft
5. Seal and fit the transmissioncase cover.
and, by turning the interior shift rod, care-
Whendoing so, pay attention to the installation
fully swivel the latter into the guide hole.
position of the dowel sleeves in the trans-
mission housing(see Page 34 -27).

~1.
Manual transmission -Actuatioln, housing Boxster
6. Pressin the ball bearingfor the inputshaft.
Place the pressure disc -A -of the special

tool onto the ball bearing.
Putthe special tool 3235 behindthe teeth

for the clutch plate on the input shaft and
pretensionwith the two screws -B -.Here,
the screws support themselvesin the two re-
cesses of the pressure disc.
Press in the ball bearing as far as it will go

by alternatelytightening the two screws.
Note
Tighten the screws -B -only by 1/2 of a turn
each so that the ball bearing is not tilted and
thereby damaged.
47 -96


34 55 37 Disassembling and assembling transmission case cover (transmission G

86)
Tools

1 Strikingtool VW771
2 Threadedpiece VW771/15
3 Pressurepiece 9247/1
4 Pressurepiece VW295 a
5 Pressurepiece 3005
6 Pull-intool andextractor P 254
7 Threadedadapter Standard
(MIO/M8) (e.g. Messrs. Kukko 18 -008 A)
34 55 37 Disassembling and assembling transmission case cover (transmission G 86) 34 -19


Diisassembling and assembling transmission case cover (transmission G 86)
14 17 .""""~-15
16
~ ~~..""'I~:~~,"
./ ~ I
I
'"""""'~~')
,..
.~ \ . v
.~ ~
~. .
A/.~'/~r.)~t~
~~J --~1
I
12
I
13 I~
I
I ~ I
~
i:""~::.P"'1 5
6
i 2 3 4
34 -20 3~ 55 37 Disassembling and assembling transmission case cover (transmission G 86)

~
'1
1
~
Note:
Oil collecting vessel 1 Push in until the lock

engagesin the trans-
mission case cover hole.
The collecting vessel
must face upwards.
2 Snap ring 1
3 Washer 1
4 Reverseidler gear 1
Needle roller bearing 2

6 Thrust washer 1
7 Retainingsleeve 1 Force out with a suitable Do not reinstall (required
internal puller and special only during manufacture
tool VW771 in Production)
8 Tapered roller bearing 1 Removewith the special Press in with the special
outer race tools VW 771, VW771/15 tool 3005 and a suitable
and standardthreaded plunger (e.g. special tool
adapter WI 407)
9 Adjusting shim "S4" x Note the thickness for Measureagain if
refitting necessary(see Page
39 -15 and 39 -25)
10 Pressure plate 1
11 Rubber disc 1 If necessary,drill a hole in Replace if necessary
the disc and pull out with a
sheetrnetalscrew
34 55 37 Disassembling and assembling transmission case cover (transmission G 86) 34 -21


Note:
12 Needle roller bearing 1 Removewith the special Alwaysreplace. Press in

tools VW771, VW771/15 in the correct position
and a suitable internal using the special tool VW
puller (e.g. Kukko21/4, 295 a and a suitable
22 -28 mm). tubular piece (e.g. special
Destroythe plastic sleeve tool VW420). The large
No. 13 before fitting the collar of the special tool
puller. VW295 a faces the
needle roller bearing
13 Plasticsleeve 1 Is destroyed during removal Always replace
14 Bushing 1 Removewith the special Press in with the special

tools VW 771, VW771/15 tools 9247/1 and P 254
and a suitable internal
puller (e.g. Kukko 21/4,
23.5 -30 mm)
15 Sh~ftseal 1 Lever out Fill the chamber between

the dust lip and sealing
lip with multi-purpose
grease and drive in with
a suitable tubular piece
(e.g. special tool VW423)
16 To~x screw 1 Must be removed only if Tighteningtorque 35 Nm

the reverse idler shaft is (26 ftlb.)
replaced
17 Transmissioncase cover 1 If the cover is replaced,
remeasurethe adjusting
shim "S4"
(see Page 39 -25).
Seal with Loctite 574
34 -22 34 55 37 Disassembling and assembling transmission case cover (transmission G 86)


Instructions for disassembly and assembly
Disassembly
1. Removethe outer race for the small tapered
roller bearing using special tools VW 771, VW VW407
771/15 and a commerciallyavailable
threaded adapter (MID/M8).
3005
-
'0
ki' 57 -96
\
2. Press in the needle roller bearing for the input
\,\\
shaft in the correct position with special tool
~1\ \fIN 295 a.
Measurethe installationdimensionfrom the
_\\ cover upper edge to the bearing upper edge.
56-96
Assembly
1. Press in the outer race for the small tapered
roller bearing using special tool 3005. ,t ~
~
6"~,
@
~(,
"'W':'
/(Q
I'a"=216mm 58 -96
.
5
~
34 55 37 Disassembling
Printed in Germany, 1996
and assembling transmission
9863419
case cover (transmission G 86) 34 -23
3. Drivein t~e sealingring for the interiorshift

rod. I
"a" = 1 mmi 59- 96
34 -24 ~4 55 37 Disassembling and assembling transmission case cover (transmission G 86)


34 37 37 Disassembling and assembling thl~ transmission housing (transmission

G 86)
Tools
1
mmf:J:mmm
~ 2 r; I 6 7
\\~:~
3 9
4 ~ ~;:~-:;*~~~~V;:;id 6)12
?- -0)
5
~ ~
10 11
~
13
~
34 37 37 Disassembling and assembling the transmission housing (transmission G 86) 34 -25


1 Stri~ingtool \IW 771
2 Bridlge \!IN 771/29
3 Pu"lintoolandextractor P 254
4 Driv~~nmandrel \!IN295
5 Hoqk VW681
6 pre$sure piece 9247/4
,
7 Pre$surepiece 3128
8 Pre$suredisc VW511
9 Pre$surepiece 30 -205
.
10 Pre$surepiece 40-202
Pre~surepiece 9247/1
12 DrivF~n
mandrel V'N 195
13 Thr~adedpiece V'N771/15
34 -26 34 37 37 Disassembling and assembling the transmission housing (transmission G 86)


Disassembling and assembling the transmission housing (transmission G 86)


Note:
r~o. Designation Qty. Removal Installation
1 Oil ~rainplug 1 See Page 34 -1 Tighteningtorque 25 Nm

(18 ftlb.)
2 Tor~ screw 2 Tighteningtorque 10 Nm
(7 ftlb.)
3 To~ screw 1 Tighteningtorque 25 Nm
(18 ftlb.)
4 Tab Iwasher
5 Rev,rsing
lightswitch 1
6 Torqidalsealingring 1 Alwaysreplace,lightlyoil
7 Capl
8 TaPfredrol~erbearing 1 Pulloutwith special Press in with a suitable

out~rrace tools 3128 andWI 771/29 pressure piece
9 Adjulsting shim "S3" x Notethe thicknessfor rein- Remeasureif necessary

stallation (see Page 39 -19)
10 Needle roller bearing 1 Pressoutwith specialtools Press in in the correct

VW295 and 40 -202 position with the special
tools VW40 -202 and
VW 295 (do not strike),
Whendoing so, the
labelled side (greater
sheet thickness)faces
the pressurepiece
11 Bus~ing 1 Removewith the special Press in with the special
tools V'N771, VW771/15 tools 9247/1 and P 254
and a suitable internal pul-
ler (e.g. Kukko 21/4,
23.5...30 mm)
12 Tor~ screw 2 Tighteningtorque 20 Nm

(15 ftlb.)


Boxster Manual transmission -J'ctuation, housing
Note:
13 Cover 1 Removewith the special

tools VW771, VW771/15
and a suitable internal
puller (e.g. Kukko21/3,
18.5...23.5mm)
14 Torx screw 1 Tighteningtorque 10 Nm
(7.5 ttIb.)
15 Lock (5th and reverse gear)
16 Toroidalsealingring 1 Alwaysreplace,lightlyoil
17 Shaft seal 1 Pullout with the special Fill the chamber between
tool vnN681 (also possible the dust lip and sealing
with transmission installed) lip with multi-purpose
grease. Drive in in the
correct position using the
special tool VW 195 (5.5
mm under the upper
edge of the cover)
18 Tapered roller bearing 1 Drive out with a suitable Press in with the special
outer race (small) * aluminiumor copper tools
mandrel (~6...8 mm) 30 -205 and VW295
19 Adjusting shim "S2" x Note the thickness for Remeasurethe thickness
reinstallation if necessary
20 Adapter
21 Balljournal 1 Tighteningtorque 25 Nm
{I8 ftlb.}
22 Sleeve 2 Press in in the correct
position
23 Transmission
housing
24 Oil filler screw 1 Tighteningtorque 25 Nm
(18 ftlb.)
25 Shaft seal 1 Sameas No. 17 same as No. 17
26 Taperedroller bearing 1 Sameas No. 18 Press in with the special

outer race (large). tools VW511 and VW295
34 37 37 Disassembling and assembling the transmission housing (transmission G 86) 34-29


Manual transmission -Actuation, housinger Boxster
Note:
27 Adjusting shim "SI" x Same as No. 19 Same as No. 19
28 Coverfor finaldrive. 1 Seal with Loctite 574
Note
If the parts marked with an .(asterisk) are replaced, readjustmentis necessary(see Page 39 -11).


Instructions for disassembly and assembly (transmission G 86)
Disassembly Assembly
1. Pull out the tapered roller bearing outer race 1. Press in the needle roller bearing for the input
with the special tools 3128 and VW771/29. shaft in the correct position, using the special
tools VW295 and 40 ~202 (do not strike).
A = sqrew MID x 135 92 -96
t
94 -96
2. pre s out the needle roller bearing for the

inp shaft with the special tools VW295 and Dimension"a" from the bottom edge of the rule
40 202. to the upper edge of the needle roller bearing
39.5 :t 0.3 mm.
y
~~
2T
93 -96


II!
2. Press-in~epth of the sleeve for transmission

venting. I
96 -96
1 -Plastic bushing
2 -Toroidal sealing ring
a = 21:t q.5 mm 95 -96 3 -Bushing with lock for 5th and reverse
gears
3. Assembl~instructions for the lock for 5th 4 -Spring
and reve~segears
4. Assemblyend position of the lock for 5th
Insert t e spring "4" into the plastic bushing andreversegears.
"1" and urn it counterclockwiseunder slight
pressur until the spring engages at the The lug (arrow A) of the bushingfor 5th and
base of the plastic part. Positionthe bushing reverse gears must alwayscome to the stop
"3" onto the spring so that the bent spring opposite to the groove (arrow B) of the plas-
end lies in the groove providedfor that pur- tic bushing.
pose. P ess the spring together with the
bushing"3", tighten by approx. 1 turn
counter lockwise (to the left) until the lug of
the bus ing "3" is above the groove in the
plastic ushing. Press the lug of the bushing
"3" into he groove of the plastic bushing"I"
as far a the stop surface. Turn the bushing
"3" cloc wise (to the right) and release it.
The bus ing "3" springs into the assembly
end position.
97 -96
34 -32 ~4 37 37 Disassembling and assembling the transmission housing (transmission G 86)

I 9863425 Printed in Germany, 1996

Boxster Manual transmission -Gears, shafts, into gearsh.
35 40 37 Disassembling and assembling thl~ input shaft (transmission G 86)
Tools
0 4

1 Tubular piece 9238
2 Pressureplate VW 401
3 Pressureplate VW402
4 Measuringbridge 3167


Manual transmission -Gears, shafts, into gearsh. Boxster
D'isassembling and assembling the input shaft (transmission G 86)
{:)
1 ""~ 21
1 """""""'IB
20
./
1 i (iff'~19
~~ "" 1
0 2
'e~,-"'-""-::---=
~---/ - 3
~4
'I~I---""
(::) "" 5
6 9==7
8
~I~r---~~~ 11
0
. 35-2 35 40 37 Disassembling and assembling the input shaft (transmission G 86)


Note:
1 Snap ring 1 Mark for refitting Remeasurethe snap ring

if the input shaft and 5th
gear fixed gear whee! are
to be replaced
2 5th gearfixedgearwheel Press off above the 4th Heat up to approx.
gear loose gear wheel 100 °C and press on in
the correct position
3 Needle-roller
bearing 1 Markfor refitting Fit with the same gear
wheel
4 4th gear loose gear wheel 1 Insert spring before as-
sembly
5 4th gear synchronizingring 1 Markfor refitting Check for wear. Fit with
the same gear wheel
6 Selectorsleeve 1 Pay attention to the instal-
lation position
7 Snap ring (color blue) 1 Markfor refitting Remeasurethe snap ring
if the input shaft and syn-
chronizing elementNo.8
are to be replaced
8 Synchronizingelement 1 Press off Heat up to approx.
100 °C and press on
{high collar faces the 3rd
gear loose gear wheel}
9 3rd gear synchronizing
ring 1 Sameas No.5 Same as No.5
10 3rd gear loose gear wheel 1 Same as No.4
11 Snap ring (color brown) 1 Mark for refitting Alwaysthe samethick-

ness
12 Needle-rollerbearing 1 Sameas No.3 Sameas No.3
35 40 37 Disassembling and assembling the input shaft (transmission G 86) 35.3


1
Note:
13 Inp~tshaft 1 If the input shaft and ball

bearing No. 15 are to be
replaced,the snap rings
No. 14 and No. 16 must
be remeasured
(see Page 35 -9)
14 Sn~pring 1 Mark for refitting Remeasurethe thickness

if necessary
(see Page 35 -9)
15 Ballbearing 1 See Page 34 -14 See Page 34 -14
16 Sn~pring 1 Sameas No. 14 Sameas No. 14
17 Ne~dle-roller
bearing 1 See Page 34 -28 See Page 34 -28
18 Tralnsmission
housing
19 Ne,dle-roller
bearing 1 See Page 34 -22 See Page 34 -22
20 Pla~ticsleeve 1 See Page 34 -22 See Page 34 -22
21 Tr~nsmission
casecover 1
35 -4 35 40 37 Disassembling and assembling the input shaft (transmission G 86)


Disassembly 2. Pressoff the synchronizing

elementsfor the
3rd and4th gearsusinga suitableseparating
Note device(e.g.Kukko17/2, 22...115mm).
Since snap rings of different sizes and thick- Note
ness s are used, the individualsnap rings must
Before fitting the separating device, press the
be id ntified (e.g. with numbers),
synchronizingring for the 3rd gear (arrow)to
The t ickness of the individualsnap ring must
the loose gear wheel for the 3rd gear.
be de ermined again if a directly affected compo-
nent i replaced.
1. Pr~ss off the 5th gear fixed gear whee! using

a SU
j itableseparating device (e.g. Kukko 17/2,
22..115 mm).
VW402
A = Separatingdevice 89 -96
A = ~eparating device 88 -96


Assembly! 3. Installthe selector sleeve so that the slant

1. Check the synchronizingrings for wear. (arrow 1) faces the 4th gear and the offset
To do this, press the ring into the shift sleeve side (arrow 2) faces the 3rd gear.
and measurethe gap dimension"a" with a
I
feeler gauge in positions A, 8 and C.

Add up t~e measured valuesand divide by 3.
The value obtained must not be below
O.5mm.1
r1
~ 83 -96
c B
4. Determinethe snap ring for the 4th gear.
To do this, determine the thickest ring which
can still just be used.
1162 -35
2. Insertthe spring into the loose gear whee! so

that the angled end engagesin the hole.
85 -96
1179 -35
35 -6 35 40 37 Disassembling and assembling the input shaft (transmission G 86)


Note
Deter~ine the snap ring for the 5th gear in
exactlylthe same way.
5. Hea
i the synchronizing elements for the 3rd
and 4th gears to approx. 100 °C and press

on ( igh collar facing the 3rd gear loose gear
whe I).
.
"."
/
VW 401
"""""
"»»"'"
0' -~
6. Heatthe fixed gear wheel for the 5th gear to

f
apP x, 100 °C and press on (high collar to
the everse gear and the oil pockets to the
4th ear).
9238
VW 401

Purchased
Printed in Germany, 1996 from www.WorkshopManuals.co.uk
986351
35 40 15 Adjusting the input shaft (transmission G 86)
1. Cla~pthe inputshaftin the visewith protec- 3. With a depth gauge, measurefrom the
tiveliaws. housingto the lower input shaft groove.
2. put~ he special tool 3167 onto the 3rd gear

and position the transmission housing onto the
spe ial tool via the inputshaft.
Dimension"a" = 28.5 mm 64- 96
4. With a depth gauge, measurefrom the

housingto the bearing surface of the ball bear-
A = Specialtool 3167 62 -96
ing.
'-
...
"
"
Dimension
"b" = 26.8 mm 63 -96
3540 15 Adjusting the input shaft (transmission G 86) 35 -9


~
35 Manual transmission -Gears, shafts, into gearsh. Boxster
5. Measurelthethickness of the lower snap ring 8. Determinethe thickest snap ring which can
(No. 8, ~age 34 -14): still just be used.
Dimension"x"
x=a- ~
= 28.1 -26.8 mm
= 1.7 mm
~
6. Measurelthe
thicknessof the snapring in
accorda~ce
with the table:
Measurement thickness
result (mm)
65 -96
(mm)
1.48...1)56 1.54
1.57...1)65 1.63
1.66...1)74 1.72
1.75...1)83 1.81
1.84...1192 1.80
1.93...2(01 1.99
2.02...2~10 2.08
2.11...2(20 2.17
2.21...2~27 2.25
2.28...2~35 2.33
7. Force the snap ring and ball bearing onto the

input shaft with the special tool 30 -100.
35 -10 35 40 15 Adjusting the input shaft (transmission G 86)


35 59 37 Disassembling and assembling the output shaft (transmission G 86)
Tools
100-96

Separatingdevice e.g. Kukko17/2
2 Pressureplate VW401
3 Pressure plate VW402
35 59 37 Disassembling and assembling the output shaft (transmission G 86) 35 -11


Disassembling and assembling the output shaft (transmission G 86)
-,
8-0 iI ..
I
9-9 II
Ii.
I
35
10-. I
I /34
12--0 I
"'=='
13--@ L, .lr33:=
14J::I V- 32
r-31
15-0
20~ ~~/-1
16~ (~Z~ 2
17--0 (:, 3
18-0 'C:::)---4
0..."'-- 5
191 0---6
~;~"- 7
~11
L j ~
35 -12 35 59 37 Disassembling and assembling the output shaft (transmission G 86)


,36
--1
~
Note:
1 Tapered roller bearing 1 Using a suitable separating Heatto approx. 1000 C

inner race device (e.g. Kukko17/2), and press on with a
press off via the reverse suitabletubular piece
gear wheel (e.g. special tool
30 -100). Press again
after heat exchange
2 Reversegear loosegear 1 Insert spring before
wheel assembly
3 Reversegear synchronising 1 Mark for refitting Check for wear. Fit with
ring the same gear wheel (see
Page 35 -16).
4 Selector sleeve 1 The slant must face
the reverse gear
(see Page 35 -17).
5 Needle-rollerbearing 1 Mark for refitting Fit with the same gear
wheel
6 Snap ring * 1 Mark for refitting Remeasureif necessary
(colour blue)
Synchronisingelement 1 Using a suitable separating Heatto approx. 1000 C
device (e.g. Kukko 17/2), and press on (high collar
press off together with the facing the 5th gear loose
5th gear loose gear wheel gear wheel)
8 5th gear synchronisingring 1 Same as No.3 Same as No.3
9 5th gear loose gear 1 Same as No.2

wheel..
10 Needle-rollerbearing* * 1 Same as No.5 Same as No.5
11 Snap ring * 1 Sameas No.6 Always2.00 mm thick

(colourbrown)
12 Snapring.. 1 Same as No.6 Same as No.6

Printed in Germany. 30, 1999 986351

~~5 Manual transmission -Gears, shafts, into gearsh. Boxster
Note:
13 4th gear fixed gear wheel* * 1 Press off with special tool Heat up to approx.
VW402 laaoG and press on in
the correct position
(groove or high collar
faces 3rd gear)
14 Sna~ring * 1 Sameas No.3 Sameas No.3
15 3rd gear fixed gear wheel 1 Sameas No. 13 Same as No. 13, groove
faces 4th gear
16 2nd gear loose gear wheel 1 Same as No.2
17 2nd gear synchronising ring 1 Same as No.3 Same as No.3
18 Sele~torsleeve 1 Slant faces 2nd gear

(seePage35 -17).
19 Needle-roller
bearing 1 Sameas No.5 Same as No.5
20 Snap ring * 1 Sameas No.6 Always2.5 mm thick

(colour blue)
21 Snap ring *
1 Same as No.6 Same as No.6
(col6ur blue)
22 Synchronising element 1 same as No.7 I press off Heatto approx. 100°C

with 1 st gear loose gear and press on (high collar
wheel faces 2nd gear)
23 1 st gear synchronisingring 1 Sameas No.3 Same as No.3
24 1 st gear loose gear wheel 1 Same as No.2
25 Needle-roller
bearing 1 Sameas No.5 Same as No.5
26 Snaq ring * Same as No.6 Same as No.6
27 Tapered roller bearing 1 Press off with tapered Heatto approx. 100 °C
inner race roller bearing outer race and press on with a
and special tools VW401 suitable tubular piece
and VW402 (e.g. special tool
VW415 a). Press again
after heat exchange
35 -14 35 59 37 Disassembling anld assembling the output shaft (transmission G 86)

986351 Printed in Gemlany -30, 1999

1
Boxster Manual transmi~ision -Gears, shafts, into gearsh.
Note:
28 Output shaft* * 1 This is paired with the

crown wheel (drive set),
Readjustif replaced (see
Page 39 -13).
29 Tapered roller bearing 1 See Page 34 -30
outer race
30 Adjusting shim "S3" x See Page 34 -30
31 Retainingsleeve 1 See Page 34 -21
32 Tapered roller bearing See Page 34 -21

outer race
33 Adjusting shim "S4" x See Page 34 -21
34 Pressure plate 1 See Page 34 -21
35 Rubber washer 1 See Page 34 -21
36 Transmission
cover 1 See Page 34 -22
37 Transmission
housing 1 See Page 34 -25
* Note
Since snap rings of different sizes and thicknessesare used,the individualsnap rings must be identified
(e.g. with numbers).The thickness of the individualsnap ring must be determinedagain if a directly af-
fected romponent is replaced.
* * Cha'ngedcomponents on the transmissionDVY. Observeallocationin the case of repairs (see Parts
Catalog!ue).
35 59 37 Disassembling and assembling Ithe output shaft (transmission G 86) 35 -15


1
Ilrlstructions for disassembly and assembly (transmission G 86)
Dlisassembly Assembly
1. Check the synchronisingrings for wear.
Note To do this, press the ring into the shift sleeve
Whenrepla ing the tapered roller bearings and measurethe gap dimension"a" with a
(No.1 and o. 27), determine the installation feeler gauge in positions A, Band C.
position bet re removing the output shaft (see Add up the measuredvalues and divide by 3.
Actual Mea urementon Page 39 -17). The value obtained must not be below
O.5mm.
1. Press offl the tapered roller bearing inner race.
.
The oute~race must be used for this purpose.
'- 'B
1162_35
A = Tapere~roller bearingouterrace 116_96
35 -16 35 59 37 Disassembling and assembling the output shaft (transmission G 86)


2. Ins~rtthe springintothe loosegearwheelso Note

tha, the angledend engagesin the hole. Determinethe snap rings of the synchronizing
elements and of the 3rd and 4th gears in
exactlythe same way.
3. Installthe selector sleeves in the correct posi-

tion. The slanted side (arrow 1) faces the
reverse gear loose gear whee! (No.2) in the
case of the 5th and reverse gear selector
sleeve,and it faces the 2nd gear loose gear
wheel(No. 16) in the case of the 1st and 2nd
gear selector sleeve.
4. Determinethe snap ring for the tapered roller

bearing.
To do this, determinethe thickest ring which
can still just be used.


Final drive -Differential, differential lock Boxster
Removing and installing the differential (transmission G 86)
7 9 2
'"."(oj \ /'
~ "-
1 2 3 4 8 5 6
53.96
3!~ -2 39 09 19 Removing and installing the differential (transmission G 86)

,.
:~(
1
/"-.-
~
Boxster Final drive -Differential, differential lock
Note:
Flangedshaft 2 SeeAssemblyinstructions Greasethe snap ring and

drive it in with a suitable
mandrel (e,g. special tool
WI 295)
2 Snap ring 2 See Assemblyinstructions Alwaysreplace

(19 ftlb.)
4 Coverfor final drive 1 Seal with Loctite 574
5 Differential 1 Can also be removed

without removingthe
transmission
6 Speedometer-drivegear 1
7 Tachometer sensor 1
8 Toroidal sealing ring 1 Alwaysreplace, lightly oil
9 Transmissionhousing 1
* Note
In this transmission,
the speedometer-drive
gear andtachometersensorhaveno function.
39 09 19 Removing and installing the differential (transmission G 86) 39 -3


Final drive -Diffl~rential, differential lock Boxster
Instructions for removal and installation (transmission G 86)
Removal Installation
1. Removethe flanged shaft.
To do this, place a chisel or spacer "A"under Note
the flanged shaft and pull out the flanged shaft The flanged shafts are installed with polygonal
by turning the screw "8", bearings. The rough running of these
bearings when the flanged shafts are not
installed does not indicate that the
bearings are faulty. The polygonal bearings
can be replaced only with the flanged shaft.
1. Always replace the snap ring for the halfshaft

flange. To do this, clamp the flange with
protective jaws and press out the snap ring
with the new snap ring "A".
\i
39250001
A=New snap ring 39250002

B=Hexagon-headbolt
2. Greasethe snap ring thoroughlyand drive in

the halfshaftflange.
39 -4 39 09 19 Removing and installing the differential (transmission G 86)


Boxster Final drive ., Differential, differential lock
39 09 37 Disassembling and assembling the differential (transmission G 86)
Tools
lO~
'~~~~;~~~~~~
?
c
,
E
39090001

A Pressure piece VW472/1
B Pressure piece P263
c Pressuredisc VW511
D Pressure piece 2050
E Drive~nmandrel VW295
39 09 37 Disassembling and assembling the differential (transmission G 86) 39 -5

Printed in Germany -3D, 1999 986395

I)isassembling and assembling the differential (transmission G 86)
~,?' ~.\
~
,~
r
~-'~:::~1
-
17
\~~~~~~ -
;~
~,~~~i~~;~~~~~~=~:;;~~~~~~==
-= ~ -===~?J=
c \-." Q ~ ~
16 :~~~~ _!!-
5 _..:~~
3 -_= ~_4~
~
5
9 "
11
7~~3~ 4
8 . ~G~2
10 ~~, 1
12
13
14
49-R-96
./
---0:-
~
~~9 -6 39 09 37 Disassembling and assembling the differential (transmission G 86)


1
'\':"-"":~.
Note:
1 Speedometer-drivegear 1
2 Tapered roller bearing 1 Removewith commercially Heat to approx. 1000 C,
inner race' availabletwo-arm puller and put into position and
special tool P 263 press again after heat
exchange
3 Tapered roller bearing 1 Same as No.2 Sameas No.2
inner race *
4 Crown wheel screw 10 Always replace. The

thread must be dry and
grease-free.Tighten
crosswise with 60 Nm
(44 ftlb.) and then
continueturning with a
rotational angle of 45°,
5 Crown wheel' 1 Force off with a mandrel If required, heat up to
through the threaded holes approx. 1000 C
6 Dowel pin 1 Drive in in the correct
position
7 Axle 1
8 Differential bevel gear 2
(small)
9 Differentialbevel gear 2
(large)
10 Thrust washer assembly 1 Insert with gear oil
Differentialhousing* 1
12 Tapered roller bearing 1 Drive out using a suitable Press in with special
outer race aluminiumor copper tools VW511 (or 2050)
mandrel(0-6...8 mm) and VW295
13 Adjusting shim "S1" x Note the thickness for Remeasurethe thickness
installation if necessary
14 Coverfor final drive. 1 Seal with Loctite 574


Note:
15 Tapered roller bearing 1 Sameas No. 12 Drive in with

outer race special tool VW472/1
16 Adjusting shim "S2" x Same as No. 13 Sameas No. 13
17 Transmissionhousing. 1
* Note
If the parts marked with an * (asterisk)are replaced, readjustmentis necessary(see Page 39 -13).
39 -8 39 09 37 Disassembling and assembling the differential (transmission G 86)


Disassembly
1. Forcethe crownwheeloff the housing.
c:..:>
c:..:>
<..) ("")
51 -96
2. Heat up the crown wheel to approx. 100 DC

and put it into position.
50 -96
Assembly
1. Installthe differentialbevelgears.
Insertthe thrust washer assemblywith hy-

paid gear oil (Burmah-OilTAF 21),
Oil the differential bevel gears thoroughly.
Insertlargedifferentialbevelgearsandfix
them with the flanged shafts (without snap
ring).
52 -96
Insertthe small differentialbevel gears offset A = Use centering pins (shop-made)
by 1800 and swivel them in by turning the for guidance.
flangeshafts.
Alignthe thrustwasherassemblyandsmall
differentialbevelgears.
Insertthe axleandsecurewith a dowelpin.


39 08 15 Adjusting the drive set (transmission G 86)
Tools
18O_99
39 08 15 Adjusting the drive set (transmission G 86) 39-11

Purchased
Printed in Germany -30. 1999 from www.WorkshopManuals.co.uk
986395
J'djusting the drive set (transmission G 86)
lrools
1 Centring disc VW 385/4
2 Centring disc VW 385/3
3 Universalmaster gauge VW 385/30
4 Dial gauge Commerciallyavailable(see

Workshop EquipmentManual)
5 Dial gauge Commerciallyavailable,measuring
range 3 mm (see Workshop
EquipmentManual)
6 Gaugeplunger V'N 385/14
7 Dial gauge extension V'N385/56 30 mm long
8 End plate V'N 385/17

9 Gauge holder V'N 387
10 Clampingsleeve VW521/12
11 Adjushnentdevice VW 521/4
12 Measuringlever VW388
13 Torque gauge Commerciallyavailable0...600 Ncm

(see Workshop EquipmentManual)
14 Dial gauge extension VW382/10 6.0 mm long
15 Dial gauge extension VW385/15 9.3 mm long
16 Measuringmandrel VW385/1
17 Holder VW792/1
18 Holder 3177
19 End plate V'N385/33
20 Lever VW296
:39 -12 39 08 15 Adjusting the drive set (transmission G 86)


Adjusting the drive set (transmission G 86)
General
Careful adjustmentof the output shaft and crown wheel are crucial to the service life and smooth running
of the final drive. Therefore, output shafts and crown wheels are paired with each other as early as during
manufactureand are checked by special inspection machinesto ensure that the tooth bearing is in a
good position and that there is low noise in both rotation directions.
The deviation"r" referred to the master gauge "Ro"is measuredfor the drive sets supplied as spare
parts and is recorded on the outer circumference of the crown wheel. Everydrive set (output shaft and
crown wheel) must be replaced only together.
39 08 15 Adjusting the drive set (transmission G 86) 39 -13

Printed in Germany. 1996 986395

Aldjustment and labelling of the drive sets, (transmission G 86)
173 -96 155 -96
KD drive sets Drive set in the series

1 -Identification "0937" meansOerlikondrive
set with the transmissionratio of 35 : 9. Note
In the series, the position of the output shaft is
2 -Pairing number (312) of the drive set, determinedby the dimensionPo (center of the
crown wheel to the rear of the output shaft
3 -Deviation "r" referred to the master gauge of head).The labellings of the deviation"r" on the
the special inspectionmachineused in pro- crown wheel and the pairing number are not
duction. The deviation"r" is always stated in present. Due to the deviation"r" not being
1/100 mm. given, it is necessarythat, before the output
Example:"25" means r = 0.25 mm
shaft is replaced,to carry out an actual measure-
ment if parts are being replaced which directly in-
Ro-Length of the used master gauge of the
fluence the installationposition of the output
special inspectionmachine.
shaft (see Page 39 -17).
"Ro" = 59.65 mm
x -These details are not required in the series.

R -Actual dimensionbetweenthe crown wheel
axis and the front side of the output shaft at Po- Adjustmentdimensionfor the series.
the point of maximumsmooth runningfor
this one drive set.
Vo -Hypoid offset
39 -14 39 08 15 Adjusting the drive set (transmission G 86)


Adjustment overview (transmission G 86)
Whencarrying out assemblywork on the final drive, readjustmentof the output shaft and crown wheel or
drive set is necessaryonly if parts are being replaced which directly influencethe adjustmentof the final
drive. In order to avoid unnecessaryadjustmentwork, pay attention to the following table:
Thefollowingmust"" crown wheel output shaft output shaft output shafts

beadjustea (S1 + S2) ($3 + S4);ion (S3 + S4) adjusting shim
over overactual only S4
Replaced Dimen "r" measurement
part
Transmission x x
housing*
Transmission
case x
cover
Differentialhousing x
Taperedroller bear- x
ing for output shaft
Tapered roller bear- x

ing for differential
Driveset x x
Cover for final drive x
If the transmissionhousingis replaced, it is also necessaryto adjustthe input shaft

(see Page 35 -9).


Appropriate sequence for readjusting the drive set (transmission G 86)
-
~
~
~
154 -96
Sl = Adjusting shim for crown wheel S3 = Adjustingshimfor drivepinion

S2 = Adjusting shim for crown wheel S4 = Adjustment shimfor drivepinion
If the output shaft and crown wheel haveto be 3. Divideup the total disc thickness"Stot" in S3
adjusted, it is best to follow the sequence below and S4 so that the measurementfrom the
in the interest of rational working: crown wheel center to the front of the drive
pinion correspondsto the installationdimen-
1. Determinethe total disc thickness "Stot" (Sl sion "R" measuredduring production.
plus S2) for the correct preload of the tapered
roller bearings/differentials. 4. Divideup the total disc thickness "Stat" in Sl
and S2 so that the stipulated circumferential
2. Determinethe total disc thickness "Stot" (S3 backlashis present betweenthe crown wheel
plus S4) for the correct preload of the tapered and output shaft.
roller bearings/outputshaft.


H
Boxster Final drive.. Differential, differential lock
Theaim of the adjustment

is to againachieve Determinillg the installation position of the
the positionof maximumsmoothrunningwhich output shaft (actual measurement)
was determinedin productionon the testingma- This work must be carried out only if the devia-
chine. tion "r" is not given on the crown wheel and if
parts are to be replaced which directly influence
The greatest possible care and cleanlinessdur- the output shaft position. These are: Both
ing all assemblywork and measuringpro- tapered roller bearingsfor the drive pinion and
cedures are essential requirementsfor a perfect the transmission housing.
result.
Removethe differential,
Completethe universalmeasuring mandrel,as

described on Page 39 -22. Insert it into the
transmissionhousingand measurethe dif-
ference to "Ro"(max. deflection/reversingpoint).
The measuredvalue corresponds to the devia-
tion "r". Note the value.
After replacingthe parts, adjust the output shaft

as described. Whendoing so, use the deviation
"r" determinedwhen measuringthe adjusting
shim "S3".

Adjusting the output shaft (transmission G 86)
Readjustmentof the output shaft in accordance Fit the inner races for the tapered roller bear-
with the instructions below is necessary only if Ings
the drive set is replaced. If other parts which (see Rep. Gr. 35, Disassemblingand assem-
also influencethe output shaft position are bling the output shaft).
changed,make the adjustmentvia the previously Secure the lower tapered roller bearing
determined installationposition. (arrow).
(See Page 39 -17 for actual measurement).
1. Total disc thickness Stat. (S3 + S4).
Preloadof the taperedroller bearings/output

shaft
Install the outer races for the tapered roller

bearings without adjusting shims in the trans-
mission housingor in the transmissioncase
cover. Alwaysuse rubber washer and press-
ure plate for measuringthe disc thickness
and for measuringthe S4 disc.
172 -96
Note
Pressureplatesof variousthicknessescanbe in- Placethe transmission
housingon the work-
stalled. bench.
Put the output shaft into the transmission

housing.
Put on the transmissioncase cover and

tighten the screws with 25 Nm (18 ftlb).
Turnthe gearsso thatthe transmissioncase

housingfacesdownwards.


Using the special tool VW296, press on the Turn the transmissionthrough 1800 so that
output shaft head until the tapered roller the transmissioncase cover faces upwards.
bearinglouter race fits closely in the trans-
missionicase cover.
158 -96
156 -96 Turn the output shaft manuallyso that the

tapered roller bearing settles.
Turnth~ outputshaftmanuallyuntilthe
tapered roller bearing settles. Read off the measurement result on the dial
gauge(e. g. 1.45 mm).
Assemblethe measuringtool and set the
dial gauge with 1 mm preload to "0", Measure the total disc thickness "Stot."
(53 + 54)
Stat. = Measurementresult
+ pressing
;0
~ I" Pressing
I (constantvalue) 0.15 mm
Measurementresult +1.45 mm
Stat. 1.60mm
0 -o.~
157 -96
39 -20 3908 15 Adjusting the drive set (transmission G 86)


1-
2. Checking the preload of the tapered Note

roller bearings for the output shaft.
The dial gauge may now display a value of
0.08 mm to 0.15 mm with correctly
Install the measuredtotal disc thickness
selected adjustingshims.
(example 1.60 mm) behindthe tapered roller
bearing outer race of the transmissioncase 3. Determining the dimension "e"
cover ($4 side).
Allow the measuredtotal disc thickness
Put on the transmission case cover and
(in the example 1.60 mm) into the tapered
tighten the fastening screws with 25 Nm
roller bearing outer race in the transmission
(19 ftlb.). case cover (S4 side).
Turn the output shaft a few times so that the

Refit the transmissioncase cover.
tapered roller bearings settle.
Turn the output shaft a few times so that the
Note
tapered roller bearings settle.
Screw the screw into the shaft head in order to
turn the output shaft. Adjustthe setting collar of the special tool
VW385/1 to the dimension"a" = 35 mm,"
Fit the measuring tools.
Adjust the movable setting collar
to the dimension "b" = 65 mm.
~ ~
39080001
Set the dial gauge (3 mm measurement 39080002
range)with 1 mm preload to "0",
Undo the screws of the transmissioncase

cover and read off the dial gauge.


Completethe universalmeasuring mandrel Removethe master gauge and insert the

as shown in the illustration. measuringmandrel with the dial gauge
downwardsinto the housing.
Put on the cover for the final drive and

secure it with 4 screws.
Pull out the 2nd centring disc via the

movable setting collar far enough so that the
measuringmandrel can still just be turned
manually.
Measure dimension "e",
Turn the measuringmandrel until the dial

gauge tip touchesthe end plate on the
39080003 output shaft head and displays the max,
deflection (reversingpoint), The measured
Set the master gauge, special tool 385/30, value is the dimension "e"(black number
to the dimensionRo = 59.65 mm and range),
place on the measuring mandrel.
Set the dial gauge (3 mm measurement Example0.46 mm
range)with 1 mm preload to "0".
Place the end plate, special tool

IT="'I
VW385/33, onto the output shaft head.
L- -.,)
"~I
- 1M
3908005
39090004
3~~ -22 39 08 15 Adjusting the drive set (transmission G 86)


Arrangementof the measuringtools for Discs of 0.55 mm...l.05 mm thickness are

determining dimension"e". available(0.05 mm increments).
Differenttolerances allowthe required disc
thicknessto be measuredexactly.
5. Determining the thickness of the

adjusting shim "54"
S4 = Stat. -S3
Example
Total disc thickness 1.60 mm

Disc thickness "S3" 0.64 mm
Disc thickness "S4" = 0.96 mm
Note
Pressure plates of 14.8 mm or 15.3 mm can
be installed.
39080006 Discs of 0.45 mm...l.49 mm thickness are

available(0.04 mm increments).
4. Determining the thickness of the Different tolerances allow the required disc
adjusting shim "53" thicknessto be measured exactly.
S3 = e + r 6. Performing a check measurement

(checking dimension "r").
e = Measuredvalue (max. deflection)
Install the output shaft with the measured
= Deviation(given in 1/100 mm on adjusting shims S3 and S4 and turn several
the crown wheel or is determinedin times in both directions.
the actual measurement)
Example
Value "e" read off on

the dial gauge 0.46 mm
Deviation "r" written
on the crown wheel +0.18 mm
Disc thickness "S3" =0.64 mm


Final drive -Diff,erential, differential lock Boxster
Insert a universalmeasuring mandrel (special

tool) and carry out a check measurement.
39080005
If the selected adjusting shims are the

correct ones, the dial gauge must display
the value of the written deviation "r" (in the
example 0.18 mm) with a tolerance of
:t 0.04 mm when read off counterclockwise
(red number range).
.

Boxster Final drive ..Differential, differential lock
Deten11ining "54" again (transmission G 86)
Note 6. Removethe output shaft and outer race of the

If only the transmissioncase cover is replaced, tapered roller bearing with the pressure plate,
only the adjusting shim "S4" must be measured adjustingshim and rubber washerI and install
them in the newtransmissioncase cover
again.
(see Page 34 -20).
1. Cle~nthe housingmatingface.
7. Place the dial gauge on the new transmission
2. Place the output shaft in the transmission case cover with the special tool VW 387 as
case cover and turn so that the tapered roller shown in Figure 165 -96 and read off the
beqring settles. value on the dial gauge (in the example
0.88 mm).
.
3. As$emblethe measuringtools
Example
Prel 1.00 mm
~ VW 387 Read-otfvalue
X =
0.88 mm
0.12 mm
Adjustingshim $4 0.77 mm
Value X + 0.12 mm
New shim thickness $4 0.89 mm
Note
If the read-offvalue on the dial gauge is greater

than 1.00 mm, the thickness of the adjusting
shim "S4" must be reduced by the value X.
165 -96
8. Fit the transmissioncase cover and check the

4. Set the dial gauge (3 mm measuring range)to preload of the tapered roller bearings for the
"a" with 1 mm preload. output shaft (see Page 39 -21).
5. Carefullyremove the special tool VW 387 with

the dial gauge.
Note
Handlethe holder and dial gauge with care so
that they do not become misadjusted.

cad
Adjusting the crown wheel (transmission G 86)
Determining the total disc thickness "5tot." 6. Secure the special tool VW 387 with the dial
(51 + 52). gauge and extensionto the housing,and set
Readjustmentof the crown wheel is necessary if to "0" with 1 mm preload.
the transmission housing,

the cover for the final drive,
the tapered roller bearings for the
differential, (the differential housing)
or the drive set
are replaced.
Note
The output shaft must be removed in order to
determine the preload of the tapered roller
I
bearings on the differential.
1. Removethe sealing rings and tapered

roller bearing outer races for the differential A = Dial gauge extension, 182_99
and take out the adjusting shims approx. 30...40 mm long
(seelPage 34 -27). 7. Move the differential up and down. Read off
and note the play at the dial gauge.
2. Install the tapered roller bearing outer races
Example: 1.42 mm
without adjusting shims (see Page 34 -27).
3. Put the differential without the

speJdometer-drivegear into the housing, put
on the cover and tighten all screws with the
stipylated tightening torque.
4. Fit the special tools 521/4 and 521/12.
5. Place the special tool VW 385/17 onto the

collar of the differential.
_99


Note Note
Whenmeasuringthe play, do not turn the Whenreadjustingthe drive set, also adjust
differential,otherwise the measurement the output shaft and perform a check
result will be corrupted. (see Page 39 -19).
8. Calculate"Stat.".
"Stat." = measurementresult + pressing.
Example
Measurementresult 1.42mmmrn
Pressing (constant value) + 0.50
"Stat," = 1.92 mm
9. Install the determined total disc thickness

"Stot." behindthe tapered roller bearing
outer race in the transmissionhousing.
10. Measurethe friction torque with a

commerciallyavailabletorque gauge
(0...600 Ncm (0... 53 inlb.)).
It must be 250...350 Ncm (22...31 inlb.)in
the case of new tapered roller bearings and
it must be 30...60 Ncm (2.6...5.3 inlb.) in
the case of run-intapered roller bearings
(bearingsfilled with gear oil).
~ 1-:
'--
A = Torque gauge 183_99


Adjusting the circumferential backlash (transmission G 86)
The circumferential backlash must be 0.12 mm... 0.22 mm.
1. Install the output shaft with the adjusting 6. Fit the dial gauge holder with the dial gauge
shims "S3"and "S4". so that a right angle is produced between
the dial gauge axis and the lever.
2. Insert the differential, fit the cover and tighten
all fastening screws with the stipulated
tighteningtorque.
3. Screw the special tool VW388 to the special

tool VW 521/4 and adjust the lever lengthto
72 mm with the gauge plunger (see Figure,
dimension"a").
4. Insert the adjustmentdevice with the special

tool VW521/12 into the differential and clamp
it securely.
5. Turn the differential several times in both

directions so that the tapered roller bearings
settle.
Dimension"a" = approx. 72 mm 184_99
7. Carefullyturn the crown wheel as far as it will

go via the clamping screw of the adjustment
device and set the dial gauge to zero.
Next, turn the crown wheel back and read off
the circumferentialbacklash. Note the value.

Note Example:
If the friction coefficient of the output shaft is
too lowJthe special tool 3177 must be fitted so 1 st measurement 0.84 mm
that an exact circumferential backlashcan be 2nd measurement 0.85 mm
measured. 3rd measurement 0.84 mm
The differential can then only be inserted in such 4th measurement + 0.83 mm
a way that the aperture of the bevel gears faces Total 3.36 mm
the output shaft.
Average circumferentialbacklash:
3.36 : 4 = 0.84 mm
10. Determining the disc thickness "52"

(with respect to the crown wheel)
S2 = Stat.
-Average circumferentialbacklash
+ Take-off(constant value)
Take-off= 0.15 mm
Example:
Stat. 1.92 mm
Average circumferential
8. Repeatthe measuring procedure another backlash 0.84 mm
three times after continuingto turn the crown 1.08 mm
whee!through 900 in each case. Add up the Take-off(constantvalue) + 0.15 mm
measured values and calculate the average S2 1.23 mm
circumferentialbacklash.
Withthe assembled special tool 3177, install Note
the differential offset by 1800 and repeat the Discs of 0.45 mm...I.OO mm thickness
measuringprocedure. are available(0.05 mm increments).
Different tolerances allowthe required disc
Note
thicknessto be measuredexactly.
If the individualmeasured valuesdeviate from
each other by more than 0.06 mm during this
measurement,installation of the crown wheel
or the drive set itself is not in order.
Inspectthe assemblywork and replace the
drive set if necessary.
9. Determinethe average circumferential

backlash.


11. Determining the disc thickness "SI"

(crown wheel side)
S1 = Stat. -S2
Example:
Stat. 1.92 mm
S2 1.23 mm
S1 0.69 mm
Note
Discs of 0.45 mm...I.OO mm thickness are avail-
able (0.05 mm increments).
Different tolerances allowthe required disc thick-
ness to be measuredexactly.
12. Install determinedadjusting shims uSl" on

the crown wheel side and uS2"opposite the
crown wheel.
13. Carryouta checkmeasurement. Whendoing

so, measurethe circumferential
backlash
four timesaroundthe circumference.
It mustbe 0.12...0.22mm.
Note
Theindividualmeasurement resultsmay
deviatefrom eachother by max.0.05 mm.

Technical Manual
-~,~~~ -5
Group 3
Transmission, manual transmission
Trbl86S.chp
Boxster S Table of Contents
3 Transmission, manual transmission (Boxster 51
3 Transmission
3 Technicaldata 3-101
34 Manual transmission -Actuation, housing

3435 19 Removing and installing transmission.
closure cap for selector force mechanism 34 -101
3449 19 34-107
35 Manual transmission -Gears, shafts, into gearsh.
35 50 19 I
Removing
and installingsealingring for inputshaft. . 35-101
39 Final drive -Differential, differential lock
39 22 19 I
Removing
andinstallingsealingring for halfshaftflange. . 39-101
3 Transmission, manual transmission (Boxster 5) 101

Printed in Germany -35, 1999 986STOC

3 Technical data (Boxster 51
6-speed manual transmission G86/20
34350002
Type Code letter Equipment Installed in Model year
G ~6/20 6-speed Boxster S 00
8
3 Technical data (Boxster 5) 3 -101

3 Technical'data (Boxster 5)
Key to transmission numbers
34350005
1 000410
T
Transmission type
T
Index for version
I
Serial number
within transmission number
= normal differential
3 Technical data (Boxster S) 3 -103


Technical data (Boxster 5)
Manual transmission G86/20
3 Technical data (Boxster 5) 3 -105


Technical data (Boxster 5)
Tightening torques (transmission G86/20)
Location Thread Tightening torque

Nm (ftlb.)
Screwlplug, oil drainage

and oi~filling M22 30 (22)
t
Drive haft on transmission
flange MIa 81 (60)
Clutchlslave cylinder on
transn)ission M8 23 (17)
Guide~ubefor release
bearin~ on transmission M8 24 (18)
Balljo~rnal for release lever

on tra~smission M8 25 (19)
CoverIfor final drive

on tra~smission M8 25 (19)
MI2 85 (63)
Trans~iSSion
on en~ine MID 45 (33)
Rever~inglight switch
on tra~smission M12 15(11.0)
Brack~tfor shift cables on
trans~ission MIa 45 (33)
3 Technical data (Boxster S) 3 -107


34 35 19 Removing and installing transmission -Boxster S
Tools
34350004

A Support beam 10 -222 A
B Support feet 9591/1

c Removaltool Commerciallyavailable(refer to
TechnicalEquipmentManual,
Chapter2.4, No. 21)
34 35 19 Removing and installing transmission -Boxster 5 34 -101


Removing and installing transmission
Removal I
1. Removerhufflerfor intake system.
2. Hold engine in installationposition at the trans.

port brac~et using special tools 10 -222 A
and9591(1.
34350006
8. Removedrive shafts at the transmissionand

protect the shafts againstdamage (use scrap
pieces of hose with a diameter of 30 mm).
9. Disconnectplug connectionfor the reversing-

light switch and pull the wire out of the retain-
194_96
ing clips.
10. Unscrewthe clutch slave cylinder and hang

3. Remove~iagonal braces and sheetmetal
up at the side with the hose connected.
cross me/nber.
4. Remove~tabilizer.
Warning!
5. Removerear muffler
(see servo No. 26 33 19).
& The clutch pedal must not be
pressed if the slave cylinder has
been removed.
6. Remover~ar cross member (V strut) Danger of injury from flying
piston rod.
7. Remove~eatshield.
> Affix a warning note where it can
be seen in the vehicle!
34 -102 34 35 19 Removing and installing transmission -Boxster S


L~ver off shift cables on transmissionlever 13. Placetransmissionjack under the

U~ ing a commercially available removal tool transmissionand fasten fixing strap.
(r fer to Technical Equipment Manual,
C apter 2.4, No. 21). 14. Removetransmission support with left and
right hydraulic mounts.
Note
Fasteningnut "C" (M12) must not be undone.

Otherwise,the transmission support will be
damaged.
"'"
34120001
12o1 1easethe support bracket sleeves (press

t bs in the direction indicated by the arrow)
AI
, \. -
a d carefullypull them out of the bracket.
/ ...'-1
A = Transmissionsupport 34380001
B = Hydraulicmount
C = M12 fasteningnut
34120002
Note
The shiftandcablesmustnotbe excessively
bent~r kinked.
34 35 19 Removing and installing transmission -Boxster S 34 -103


~ft
~
15. Unscrewtransmission/enginefastening Installation

screws.
Use a p(j)lygonwrench (10 mm, Note
part No.!999.571.052.02) for screw No.4.
The rear cross member (V strut) cannotbe
fitted if the rear muffler is installed.
Installationis performed in reverse order, taking

the following points into account.
1. Cleanteeth of the drive shaft and grease

with a thin coat of Olista Longtime 3 EP
(availableas spare part).
2. Ensure perfect seating of dowel sleevesin

crankcase.
34350003
16. Pull tran$missionto the rear and lower it

carefully.
3,~ -104 34 35 19 Removing and installing transmission -Boxster S


3. Carefullymove transmissionin and properly 4. Fit the clutch slave cylinder and tighten
fas~ento engine. fastening screw to 23 Nm (17 ftlb.).
Note
The bleeder valve must be opened if the piston

rod cannot be pushedback manuallywhen the
clutch slave cylinder is being installed. Connect
a collecting bottle with hose for this purpose.
5. Bleedthe clutchsystem.
Tightening torques (transmission G 86/20)
Diagonalbrace on
carrier side section
and body (MID) = 65 Nm (48 ftlb.]
Rear cross member (V strut) on

34350003
sheetmetalcross member and
body (MID) = 65 Nm (48 ftlb.
Stabiliseron carrier side

section (M8) = 23 Nm (17 ftlb.]
Stabilizer mounton
stabilizer (M1 0) = 46 Nm (34 ftlb.)
Drive shaft on transmission

flange (MID) = 81Nm (60 ftlb.
Transmissionsupport on
transmission(M12) = 85 Nm (63 ftlb.
Hydraulicmount on carrier
side section (MB)= 23 Nm(17 ftlb.J
Clutch slave cylinder

on transmission(M8) = 23 Nm (17 ftlb.]
Multiple-toothnut
34 35 19 Removing and installing transmission -Boxster S 34 -105


\8
34 49 19 Removing and installing cap for selector force mechanism -Boxster S
Tools
500_98

Mandrel P 375
34 49 19 Removing and installing cap for selector force mechanism -Boxster S 34 -107
.

I1temovingand installing cap for selector force mechanism
075_98
A -Closure Icap
34 -108 3449 19 Removing and installing cap for selector force mechanism -Boxster S

Removing and installing cap for selector force mechanism
Removal
1. Relmovetransmission,
2. Shlifttransmissionto neutral, unscrewfasten-

in~ screw "A" and remove snap ring "B",
484_98
Installation
1. Insertclosure cap and snap ring into the
housingbore.
2. Use specialtool P375 to push the snap ring

and closure cap down until the snap ring
1
3. 8 re a 3.5 mm large hole into the centre of engagesinto the groove.
th closure cap (coat drill with viscousgrease
Note
to preventdrilling chips from falling into the
tr nsmission).Screw in a sheetmetalscrew Ensure perfect seating of the snap ring,
(4.18x 25) with a large washer and lever out
the closure cap using two screwdrivers. 3. Tightenthe fastening screw for the wheel
bearing housingto 25 Nm (19 ftlb.).
4. Installtransmission.
34 49 19 Removing and installing cap for selector force mechanism -Boxster S 34 -109
Printed in Germanv -33. 1999 86534107

35 50 19 Removing and installing sealing ring for input shaft -Boxster S
c
117_97
II; Sleeve 9255

8 ~
Puller 9629/1
Q Pressurepiece 9628
.
35 50 19 Removing and installing sealing ring for input shaft -Boxster S 35 -101
Printed in Germany -35, 1999 86S35101

Removing and installing sealing ring for input shaft
Removal
1. Remove'transmission(refer to ServoNo, 5. Pulloutsealingring by screwingin the

34 35 1~). hexagon-head screw.
2. Remove'the release lever for clutch,
3. Removeguidetubefor releasebearing (
4. Screwspecialtool 9629/1 securelyinto

the sealingring.
Ir~\
139_1_97
Note
The coil spring must be pulled off the input shaft

with a wire hook if the spring shouldjump down
when removingthe sealingring.
139_97
8
35 -102 35 50 19 Removing and installing sealing ring for input shaft -Boxster S
86S35101 Printed in Germany -35, 1999

I~
Installation
1. Pu$hassemblysleeve9255 ontothe toothing 3. Drive in sealing ring with special tool 9628 as
of ,he inputshaft. far as the mounting face.
~\ ~F--
? \d
141_97 142_97
2. Fill the space betweenthe dust and sealing 4. Install guide tube for release bearing.
lips on the sealing ring with grease (e.g. Liqui - Always renewfastening screws and tighten
Moly). with 24 Nm (18 ftlb.)
5. Fitreleaseleverwith releasebearing.
6. Cleanteeth of the inputshaftandgreasewith

a thin coat of OlistaLongtime3EP.
35 50 19 Removing and installing sealing ring for input shaft -Boxster S 35 -103
Printed in Germany -35, 1999 86S35101

~-
~
39 22 19 Removing and installing sealing ring for halfshaft flange -Boxster S
Tools
B
c
128;.97
A Pull-intool andextractor P 254

B Pressure piece 9252
c Pressure piece 9247/1
39 22 19 Removing and installing sealing ring for halfshaft flange -Boxster S 39 -101

Removing and installing sealing ring for halfshaft flange -Boxster S
1 -Halfshaft flange 116_97.

2 -Snap ring
3 -Sealing ring

Removing and installing sealing ring for halfshaft flange -Boxster S
Note
The s~aling rings can also be replaced with the

transmissioninstalled.
Removal
1. Removeright halfshaftflange. To do this,

! .
plaqe a chisel or spacer "A" under the half-
shaft flange and pullout the halfshaftflange
by turning the screw "B",
135_97
2. Lever out sealingring using a suitabletool.
134_97
Note
Pullout left halfshaftflange by screwing in the
hexagcpn-head bolts "A" on alternate sides. The
bolts ~ust be supported on the rib reinforce-
mentsIof the cover (see Figure).
39 22 19 Removing and installing sealing ring for halfshaft flange -Boxster S 39 -103

Installation
1. Fill the space between the dust and sealing 3. Greasethe snap ring well and drive in the half-
lips with grease (e.g. Liqui -Moly) and drive in shaft flange using the special tools P254 and
the sealing ring up to the mountingface using 9247/1.
special to!ol9252.
2. Always replace the snap ring for the halfshaft

flange. To do this, clamp the flange in the vice
with protective jaws and press out the snap \
ring with the new snap ring "A". v
y
'- ~~~
/
\.\ 136_97
/K~
A -New snap ring 175_97
3!~ -104 39 22 19 Removing and installing sealing ring for halfshaft flange -Boxster S

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WKD 483 521

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Theintegrationof the technicalinformationpublishedin the "Boxster"TechnicalManualwith the

The "Boxster"Technical Manualconsists of 15 folders, subdividedinto the following Groups

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The"Boxster"TechnicalManualhasthe samestructurein eachfolder,with the followingbreakdownfor

Title page, "Boxster" Technical Manual

Title page: "Technical Information"

Title page: "Repair"

Followingthe Technical Information,separated by a title page, the instructions on repairs -assigned

Theinstructionson repairswill be extendedand updatedby meansof supplements.

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Group 0: Entire vehicle -General 0

Group 2: Fuel, exhaust, engine electronics 2

Group 3: Transmission, manual transmission 3

Group 3: Transmission, automatic transmission 3

Overview of repair groups

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Group 4: Running gear 4

Group 6: Body equipment, exterior 6

Group 8: Air conditioning 8

Group 9: Circuit diagrams 9

Group 9: Circuit diagrams 9

Overview of repair groups

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3 Transmission, manual transmission

35 Manual transmission -Gears, shafts, into gearsh.

35 40 37 Disassembling and assembling the input shaft (transmission G 86) 35 -1

39 Final drive -Differential, differential lock

3 Transmission, manual transmission 1

3 Technical data (transmission G 86)

5-speed manual transmission G 86

Type Code letter Equipment Installed in Model year

G 86/00 CWA 5-speed Boxster 97/98

3 Technical data (transmission G 86) 3 -1

1 Printed in Germany -30, 1999 9863_1

Technical data (transmission G 86)

Identification of the transmission G 86

Identification and construction date of the

CWA = Code letter

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Technical data (transmission G 86)

1 st gear 8 -Transmission case cover

2 -2nd gear 9 -Input shaft

3 -3rd gear 10 -Output shaft

4 -4th gear 11 -Ball bearing

5 -5th gear 12 -Differential

6 -Reverse gear 13 -Tapered roller bearing

7 -Transmission housing 14 -Tapered roller bearing

3 Technical data (transmission G 86) 3-3

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Technical data (transmission G 86/00/01J

3 Technical data (transmission G 86) 3-5

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Technical data (transmission G 86)

Screw plug, oil drainage

Guide sleeve for release

Plug, reversing light switch

Screwsfor relayshaft M22 40 (29)

Interlock (5th and reverse gears)

Crown wheel on differential

3 Technical data (transmission G 86) 3-7

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