Manual Trans., Actuation, Housing PDF

2007 Porsche Boxster S
TRANSMISSION Manual - Actuation, assembly housing
TRANSMISSION
Manual - Actuation, assembly housing
34 01 35 CHECKING AND TOPPING UP TRANSMISSION OIL - AS OF MY

2005 (BOXSTER, BOXSTER RHD)
TOOLS
Designation Type Number Explanation

angled wire hook (shop special tool 00000
made)
INFORMATION
Notes
NOTE: Fill only with oil approved by Porsche. See Spare Parts Catalogue.
PRELIMINARY WORK
Preliminary work
1. Raise the vehicle at the prescribed jacking points. Refer to 40 Tightening torques for front axle - as of MY
2005 (All Models) .
2. Remove support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All
Models) .
3. Place oil collection pan under the transmission.
CHECKING AND TOPPING UP TRANSMISSION OIL
Checking and topping up transmission oil
WARNING: Risk of scalding from hot oil
--> Let the oil cool down
--> Wear personal protective gear (goggles, gloves)
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Thursday, September 24, 2009 9:19:21
9:19:15 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Filler plug

Courtesy of PORSCHE OF NORTH AMERICA, INC.
1. Unscrew oil filler plug.
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Thursday, September 24, 2009 9:19:15 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 2: Oil level in the transmission

2. Insert angled wire hook (shop made) 00000 through the filler opening and check oil level. The oil level
must be 2 to 3 mm below the filler opening, otherwise oil must be added.
3. Clean oil filler plug and screw in with a new sealing ring.
Location Explanation Type Basic value Tolerance 1 Tolerance 2

Oil filler plug on manual transmission Tightening torque 30 ftlb.

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Fig. 3: Filler plug

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Fig. 4: Oil level in transmission

2. Push angled wire hook (shop-made) 00000 through oil opening and check oil level. The oil level must be 11
mm below the filler opening. If it is lower add more oil.

SUBSEQUENT WORK
Subsequent work
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1. Install support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All
Models) .
2. Lower the vehicle.
34 01 35 CHECKING AND TOPPING UP TRANSMISSION OIL - AS OF MY

2005 (BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
TOOLS

angled wire hook (shop special tool 00000
made)
INFORMATION
Notes
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
CHECKING AND TOPPING UP TRANSMISSION OIL
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Fig. 5: Filler plug

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Fig. 6: Oil level in the transmission

2. Insert angled wire hook (shop made) 00000 through the filler opening and check oil level. The oil level
must be 2 to 3 mm below the filler opening, otherwise oil must be added.

SUBSEQUENT WORK
Subsequent work
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Models) .
34 01 55 CHANGING TRANSMISSION OIL - AS OF MY 2005 (BOXSTER S,

BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
INFORMATION
Notes
TECHNICAL VALUES
Filling capacities

Manual transmission Filling capacity 2.8 liters
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
DRAINING TRANSMISSION OIL
Draining transmission oil
CAUTION: Transmission cannot be filled, or only insufficiently with ATF.
--> Do not start engine
--> Do not tow vehicle

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Fig. 7: Filler plug

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Fig. 8: Oil drain plug

2. Unscrew oil drain plug and drain transmission oil.
REFILLING TRANSMISSION OIL
Filling in transmission oil
1. Clean oil drain plug and screw in with new sealing ring.
Location Explanation Type Basic Tolerance Tolerance

value 1 2
Oil drain plug on manual Tightening
30 ftlb.
transmission torque
2. Filling capacity 2.8 litersFill with transmission oil.
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3. Clean oil filler plug and screw in with a new seal.

XX
SUBSEQUENT WORK
Subsequent work
1. Fit support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All Models) .
34 01 55 CHANGING TRANSMISSION OIL - AS OF MY 2005 (BOXSTER,

BOXSTER RHD)
INFORMATION
Notes
TECHNICAL VALUES
Filling capacities

Filling capacities

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
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DRAINING TRANSMISSION OIL
Fig. 9: Filler plug


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Fig. 11: Filler plug

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REFILLING TRANSMISSION OIL

value 1 2
Oil drain plug on manual Tightening
19 ftlb.
transmission torque


value 1 2
Oil drain plug on manual Tightening 30 ftlb.
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transmission torque

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SUBSEQUENT WORK
Subsequent work
34 04 19 REMOVING AND INSTALLING SHIFT LEVER KNOB - AS OF MY

2005 (ALL MODELS)
REMOVING SHIFT LEVER KNOB
Removing shift-lever knob
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Fig. 13: Unclipping leather sleeve

1. Unclip retaining frame of the leather sleeve in upward direction by pulling on the leather.
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Fig. 14: Turning leather sleeve clockwise

2. Turn leather sleeve clockwise by 90° as far as it will go.
Fig. 15: Pulling off shift-lever knob

3. Pull shift-lever knob up and off the shift lever.
INSTALLING SHIFT LEVER KNOB
Installing shift-lever knob
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Fig. 16: Pushing on shift-lever knob

1. Push shift-lever knob fully onto the shift lever.
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Fig. 17: Turning leather sleeve anti-clockwise

2. Turn leather sleeve anti-clockwise by 90° as far as it will go.
Fig. 18: Clipping in leather sleeve

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3. Clip retaining frame of the leather sleeve into the center console
34 08 19 REMOVING AND INSTALLING GEARSHIFT BRACKET - AS OF MY

2005 (ALL MODELS)
TOOLS

Locking bridge special tool P 9619
Locking bridge special tool P 9619/1
PRELIMINARY WORK
Preliminary work
1. Remove shift lever knob. --> 340419 Removing and installing shift lever knob - section on "Removing"
2. Remove center console. Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
REMOVING GEARSHIFT BRACKET
Removing gearshift bracket
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Fig. 19: Fitting locking bridge

1. Locking bridge P 9619/1 must be fitted on the gearshift bracket.
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Fig. 20: Opening bayonet lock

2. Open bayonet locks on the pre-selector and shifting connections.
Fig. 21: Disengaging shift cables

3. Disengage adjustment pin on pre-selector and shifting connections.
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Fig. 22: Unclipping supports

4. Unclip supports on the gearshift bracket.
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Fig. 23: Removing gearshift bracket

5. Unscrew nut and lift gearshift bracket up and off.
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Fig. 24: Removing locking bridge

6. Remove locking bridge.
INSTALLING GEARSHIFT BRACKET
Installing gearshift bracket
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Fig. 25: Installing gearshift bracket

1. Fit gearshift bracket and screw in nuts.

Gearshift bracket Tightening torque 10 (7.5 ftlb.) Nm
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Fig. 27: Clipping in supports

3. Clip in supports on the gearshift bracket. The support with the blue hinged tube must be fitted on the left and
the support with the black hinged tube must be fitted on the right.
Fig. 28: Engaging shift cables

NOTE: Before starting to install the gearshift bracket, ensure that the transmission is in
neutral.
4. Engage adjustment pin on pre-selector and shift connections.
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Fig. 29: Closing bayonet locks

5. Close bayonet locks on the pre-selector and shift connections.
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6. Locking bridge P 9619 must be removed.
SUBSEQUENT WORK
Subsequent work
1. Install center console. Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
2. Install shift lever knob. --> 340419 Removing and installing shift lever knob - section on "Installing"
34 12 19 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES -

AS OF MY 2005 (BOXSTER, BOXSTER RHD)
TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
4. Remove engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Models) .
7. Remove parking-brake lever. Refer to 46 61 19 Removing and installing parking-brake lever - as of MY

2005 (All Models) .
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REMOVING SHIFT AND SELECTOR CABLES
Detaching shift and selector cables at transmission
Fig. 31: Shift and selector cables

1. Lever off shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- from ball pin
and detach from supports.
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Detaching shift and selector cables inside vehicle
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2. Open bayonet locks at preselector and shift connections.
Fig. 35: Detaching shift cables

3. Detach adjustment pins at preselector and shift connections.
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Removing shift and selector cables
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Fig. 37: Pulling out shift and selector cable

1. Pull end of shift and selector cable - at transmission side - out through the opening in the engine compartment
lid.
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Fig. 38: Support

2. Remove support for shift and selector cables.
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Fig. 39: Support

3. Disengage shift and selector cables from support.
Fig. 40: Bulkhead panel threaded joint

4. Remove fastening nuts and pull shift and selector cables into the interior of the vehicle.
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Fig. 41: Shift cable at distributor pipe

1. Unclip shift cable at the distributor pipe.
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Fig. 42: Pulling out shift and selector cables

lid.
Fig. 43: Support

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Fig. 44: Support

4. Disengage shift and selector cable from support.
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INSTALLING SHIFT AND SELECTOR CABLES
Installing shift and selector cables

1. Push the shift and selector cables through the bulkhead panel from the interior of the vehicle and fit fastening
nuts.

value 1 2
Shift and selector Fastening nuts between shift and Tightening
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cables to bulkhead selector cables and bulkhead torque 7.5 ftlb.
Fig. 47: Support

2. Engage shift and selector cables in support.
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Fig. 48: Support

3. Fit support for shift and selector cables.

value 1 2
Support for shift and Fastening screw between shift and Tightening
7.5 ftlb.
selector cables selector cables and body torque
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Fig. 49: Pushing in shift and selector cables

4. Push end of shift and selector cable - at transmission side - into the opening in the engine compartment lid.
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Fig. 50: Clipping in shift cable

5. Clip in shift cable at the distributor pipe.

nuts.

value 1 2
7.5 ftlb.
cables to bulkhead selector cables and bulkhead torque
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Fig. 52: Support

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Fig. 53: Support


value 1 2
7.5 ftlb.

Securing shift and selector cables inside vehicle
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3. Engage adjustment pins at preselector and shift connections.
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4. Close bayonet locks at preselector and shift connections.
Securing shift and selector cables at transmission
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1. Engage shift -1- (grey end piece) and selector cable -2- (blue end piece) into support bracket for transmission
and press end pieces onto ball heads.
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SUBSEQUENT WORK
Subsequent work
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1. Locking bridge P 9619/1 must be removed.
2. Install parking-brake lever. Refer to 46 61 19 Removing and installing parking-brake lever - as of MY

2005 (All Models) .
3. Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
4. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of
MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Models) .
34 12 19 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES -

AS OF MY 2005 (BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S
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RHD)
TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
4. Remove engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and
installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
Models) .
7. Remove parking-brake lever. Refer to 46 61 19 Removing and installing parking-brake lever - as of MY

2005 (All Models) .
REMOVING SHIFT AND SELECTOR CABLES
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Detaching shift and selector cables inside vehicle
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2. Open bayonet locks at preselector and shift connections.
Fig. 65: Detaching shift cables

3. Detach adjustment pins at preselector and shift connections.
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Fig. 67: Shift cable at distributor pipe

1. Unclip shift cable at the distributor pipe.
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Fig. 68: Pulling out shift and selector cables

lid.
Fig. 69: Support

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Fig. 70: Support

4. Disengage shift and selector cable from support.
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INSTALLING SHIFT AND SELECTOR CABLES

nuts.

value 1 2
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cables to bulkhead selector cables and bulkhead torque 7.5 ftlb.
Fig. 73: Support

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Fig. 74: Support


value 1 2
7.5 ftlb.
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Fig. 76: Clipping in shift cable

5. Clip in shift cable at the distributor pipe.
Securing shift and selector cables inside vehicle

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3. Engage adjustment pins at preselector and shift connections.
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4. Close bayonet locks at preselector and shift connections.

SUBSEQUENT WORK
Subsequent work
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1. Locking bridge P 9619/1 must be removed.
2. Install parking-brake lever. Refer to 46 61 19 Removing and installing parking-brake lever - as of MY

2005 (All Models) .
3. Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
4. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of
MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and installing
engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
Models) .
34 35 TW TECHNICAL DATA, TRANSMISSION - AS OF MY 2005 (BOXSTER

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S, BOXSTER S RHD)
TECHNICAL VALUES
Technical data
Transmission type: G87/20
Equipment: 6-gear
Installed in: Boxster S (987)
Model Year: 2005
Transmission ratios
1st gear: 3.67
2nd gear: 2.05
3rd gear: 1.41
4th gear: 1.13
5th gear: 0.97
6th gear: 0.82
Reverse gear: 3.33
Final-drive ratio: 3.875
Filling capacities

34 35 TW TECHNICAL DATA, TRANSMISSION - AS OF MY 2005 (BOXSTER,

BOXSTER RHD)
TECHNICAL VALUES
Technical data
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Equipment: 5-gear
Installed in: Boxster (987)
Model Year: 2005
Technical data
Equipment: 6-gear
Installed in: Boxster (987)
Model Year: 2005
Transmission ratios
1st gear: 3.50
2nd gear: 2.12
3rd gear: 1.43
4th gear: 1.09
5th gear: 0.84
Reverse gear: 3.44
Transmission ratios
1st gear: 3.67
2nd gear: 2.05
3rd gear: 1.41
4th gear: 1.13
5th gear: 0.97
6th gear: 0.82
Reverse gear: 3.33

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Filling capacities

Filling capacities

34 35 TW TECHNICAL DATA, TRANSMISSION - AS OF MY 2005 (CAYMAN

S, CAYMAN S RHD)
TECHNICAL VALUES
Technical data
Equipment: 6-gear
Installed in: Cayman S
Model year: 2006
Transmission ratios
1st gear: 3.308
2nd gear: 1.95
3rd gear: 1.41
4th gear: 1.13
5th gear: 0.97
6th gear: 0.82
Reverse gear: 3.00
Filling capacities
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34 35 19 REMOVING AND INSTALLING TRANSMISSION - AS OF MY 2005

(BOXSTER, BOXSTER RHD)
TOOLS

retaining device special tool P 9624/1
PRELIMINARY WORK
Preliminary work
WARNING: Burns and scalding through hot components and fluids
--> Allow vehicle to cool down before beginning work
1. Raise the vehicle at the specified jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
2. Remove wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) .
Models) .
5. Unscrew fastening nuts for restraining cables and remove restraining cables from cross member.
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Fig. 83: Special tool

6. Screw retaining device P 9624/1 to cross member, turn spindle upwards and support engine.
REMOVING TRANSMISSION
Dismantling
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Fig. 84: Anti-roll bar

1. Loosen fastening screws between anti-roll bar and rear axle carrier side panel and fold anti-roll bar forward.
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Fig. 85: Drive shaft

NOTE: Protect drive shafts against mechanical damage (e. g. with a rubber hose which
has been cut open).
2. Remove drive shafts on transmission side. To do this, unscrew the six Allen screws joining each drive shaft
and transmission flange. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.
Fig. 86: Reversing-light switch

3. Pull off electric connector for back-up light switch.
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and disengage from supports. See Fig. 87.
Removing transmission
WARNING: If the supports are folded down, the vehicle will roll off the platform lift
when it is lowered.
--> Ensure that the platform is prevented from lowering.
--> Remove supports before lowering.
1. Place transmission jack under transmission and fasten fixing strap.
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Fig. 88: Cross member

2. Remove cross member.
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Fig. 89: Transmission support

3. Unscrew fastening screws between the transmission and the transmission support.

NOTE: The fastening nuts of the transmission support must never be loosened at the
hydraulic mount because otherwise the transmission brackets will be damaged.
4. Unscrew fastening screws between body and hydraulic mount -arrow- and remove transmission support with
hydraulic mount. See Fig. 90.
A - Transmission support
B - Hydraulic mount
C - Fastening nut (never loosen)
NOTE:  The clutch pedal must not be pressed if the clutch slave cylinder has been
removed. Danger of injury from the push rod which can be pressed out of
the slave cylinder hydraulically. Affix a warning note in the vehicle!
5. Remove the clutch slave cylinder but while doing so, do not disconnect the clutch line. Refer to 30 30 19
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Removing and installing clutch slave cylinder - 6-speed transmission - as of MY 2005 (All Models) .
Fig. 91: Engine/transmission mount

6. Unscrew fastening screws -1 to 7- and pull out transmission to the rear and downwards. See Fig. 91.
INSTALLING TRANSMISSION
Installing transmission
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NOTE: Before installing the transmission, clean splines of transmission input shaft and
grease lightly, e. g. with Olista Longtime 3 EP.
1. Move in transmission and screw in fastening screws -1 to 7- . See Fig. 92.

value 1 2
Transmission/engine Hexagon-head bolt no. 1 in Tightening 85 (63
connection illustration, M12 x 70 torque ftlb.) Nm
Hexagon-head bolt no. 2 in
Transmission/engine Tightening 85 (63
illustration, M12 x 100; with
connection torque ftlb.) Nm
washer
Transmission-engine Hexagon bolt No. 3 M12 x 90 in Tightening 85 (63
connection illustration torque ftlb.) Nm
Transmission-engine Internal serration screw No. 4 Tightening 45 (33
connection M10 x 35 in illustration torque ftlb.) Nm
Transmission-engine Tightening 45 (33
Nut No. 5 M10 in illustration
connection torque ftlb) Nm
Transmission-engine Hexagon bolt No. 7 M12 x 90 in Tightening 85 (63
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connection illustration torque ftlb.) Nm
NOTE: Before installing the clutch slave cylinder, grease the push rod with Kluberalfa
in the area of the release-lever ball socket. Part No. 000.043.304.02 (50g tube).
2. Insert clutch slave cylinder in transmission opening and screw in fastening screw. Refer to 30 30 19

value 1 2
Clutch slave Fastening screw between transmission Tightening 23 (17
cylinder housing and clutch slave cylinder torque ftlb.) Nm
3. Fit left and right transmission supports with hydraulic mount.

value 1 2
Transmission Fastening screws between Tightening 65 (43
support transmission support and transmission torque ftlb.) Nm
Fastening screws between hydraulic Tightening 33 (24
Hydraulic mount
mount and body torque ftlb.) Nm

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4. Install cross member.
Location Explanation Type Basic value Tolerance Tolerance

1 2
Cross Fastening screws between cross Tightening 65 (48 ftlb.)
member member and body torque Nm
5. Remove transmission jack.
Assembly work

1. Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support and
press on the ball pin. See Fig. 94.
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Fig. 95: Back-up light switch

2. Push on electric connector for back-up light switch.
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3. Fit drive shafts on the transmission side. For this purpose, tighten six hexagon socket screws between the
drive shaft and the transmission flange, respectively. Counter on the brake disc or activate the parking brake to
avoid simultaneous turning.

1 2
Drive Fastening screws between drive shaft and Tightening 81 (60 ftlb.)
shafts transmission flange torque Nm

4. Screw in fastening screws between anti-roll bar and rear axle carrier side member.

value 1 2
Anti-roll Fastening screws between anti-roll bar and Tightening 23 (17
bar rear axle carrier side member torque ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
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1. Remove retaining device P 9624/1 from cross member.
2. Fit restraining cables to cross member.

1 2
Restraining Fastening nut between restraining Tightening 23 (17
cable cable and cross member torque ftlb.) Nm
Models) .
4. Install rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) .
5. Mount wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
6. Check transmission oil level and top it up, if necessary. --> 340135 Checking and topping up transmission
oil
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34 35 19 REMOVING AND INSTALLING TRANSMISSION - AS OF MY 2005

(ALL MODELS)
TOOLS

Schremm 48-2 puller special tool 00000
retaining device special tool P 9624/1
PRELIMINARY WORK
Preliminary work
WARNING: Burns and scalding through hot components and fluids
--> Allow vehicle to cool down before beginning work
1. Raise the vehicle at the specified jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
2. Remove wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) . Refer to 26 33 19 Removing and installing rear silencer - as of
MY 2005 (Cayman S, Cayman S RHD) .
Models) .
5. Unscrew fastening nuts for restraining cables and remove restraining cables from cross member.
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6. Screw retaining device P 9624/1 to cross member, turn spindle upwards and support engine.
Dismantling
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1. Loosen fastening screws between anti-roll bar and rear axle carrier side panel and fold anti-roll bar forward.
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NOTE: Protect drive shafts against mechanical damage (e. g. with a rubber hose which
has been cut open).
2. Remove drive shafts on transmission side. To do this, unscrew the six hexagon socket head bolts joining each
drive shaft and transmission flange. Counter at the brake disc or activate the parking brake to avoid
simultaneous turning.

3. Pull off electric connector for reversing-light switch.
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and detach from supports. See Fig. 115.
WARNING: If the supports are folded down, the vehicle will roll off the platform lift
when it is lowered.
--> Ensure that the platform is prevented from lowering.
--> Remove supports before lowering.
NOTE: The fastening nuts of the transmission support must never be loosened at the
hydraulic mount because otherwise the transmission brackets will be damaged.
1. Place transmission jack under transmission and fasten fixing strap.
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2. Remove cross member.
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3. Unscrew fastening screws between the transmission and the transmission support.

4. Unscrew fastening screws between body and hydraulic mount -arrow- and remove transmission support with
hydraulic mount. See Fig. 106.
A - Transmission support
B - Hydraulic mount
C - Fastening nut (never loosen)
5. Lower the transmission for better access when removing the clutch slave cylinder.
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Fig. 107: Fastening nut

6. Unscrew fastening nut of exterior shift.
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Fig. 108: Pulling off the exterior shift

7. Pull off exterior shift using Schremm 48-2 puller 00000 from shifting shaft.
Fig. 109: Clutch slave cylinder

NOTE:  The clutch pedal must not be pressed if the clutch slave cylinder has been
removed. Danger of injury from the push rod which can be pressed out of
the slave cylinder hydraulically. Affix a warning note in the vehicle!
8. Unscrew fastening screw between clutch slave cylinder and transmission and remove clutch slave cylinder.
While doing so, do not separate clutch line. Refer to 30 30 19 Removing and installing clutch slave cylinder -
6-speed transmission - as of MY 2005 (All Models) .
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9. Unscrew fastening screws -1 to 8- and pull out transmission to the rear and downward. See Fig. 110.
INSTALLING TRANSMISSION
Installing transmission
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Fig. 111: Fastening transmission to engine

1. Move in transmission and screw in fastening screws -1 to 8- . See Fig. 111.

value 1 2
connection figure, M12 x 70 torque ftlb.) Nm
connection figure M12 x 100; with washer torque ftlb.) Nm
Transmission/engine Internal-serration screw no. 4 in Tightening 45 (33
connection figure M10 x 40 torque ftlb.) Nm
Nut no. 6 in figure M10
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2. Insert clutch slave cylinder in transmission opening and screw in fastening screw.

value 1 2
Clutch slave Fastening screws between transmission Tightening 23 (17
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3. Fit the external shift mechanism and tighten nut.

value 1 2
External shift Fastening nut between shifting shaft Tightening 23 (17
mechanism and external shifting mechanism torque ftlb.) Nm
4. Fit left and right transmission supports with hydraulic mount.

value 1 2
Transmission Fastening screws between Tightening 65 (48
support transmission support and transmission torque ftlb.) Nm
Fastening screws between hydraulic Tightening 33 (24
Hydraulic mount
mount and body torque ftlb.) Nm
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5. Install cross member.

1 2
Cross Fastening screws between cross Tightening 65 (48 ftlb.)
member member and body torque Nm
6. Remove transmission jack.
Assembly work
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1. Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support and
press on the ball pin. See Fig. 115.
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2. Push on electric connector for reverse gear switch.
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3. Fit drive shafts on the transmission side. For this purpose, tighten six hexagon socket screws between the
drive shaft and the transmission flange, respectively. Counter at the brake disc or activate the parking brake to
avoid simultaneous turning.

value 1 2
Drive Fastening screws between drive shaft and Tightening
60 ftlb.
shafts transmission flange torque

4. Screw in fastening screws between anti-roll bar and rear axle carrier side member.

value 1 2
Anti-roll Fastening screws between anti-roll bar and Tightening
17 ftlb.
bar rear axle carrier side member torque
SUBSEQUENT WORK
Subsequent work
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1. Remove retaining device P 9624/1 from cross member.
2. Fit restraining cables to cross member.

1 2
Restraining Fastening nut between restraining Tightening 23 (17
cable cable and cross member torque ftlb.) Nm
Models) .
4. Install rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) . Refer to 26 33 19 Removing and installing rear silencer - as of
MY 2005 (Cayman S, Cayman S RHD) .
5. Mount wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
6. Check transmission oil level and top it up, if necessary. --> 340135 Checking and topping up transmission
oil [987310 987311] --> 340135 Checking and topping up transmission oil [987120 987121 987320 987321]

Microsoft
34 35 27 REMOVING AND REFITTING TRANSMISSION - AS OF MY 2005

(BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
TOOLS

PRELIMINARY WORK
Preliminary work
1. Remove engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

(Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as
of MY 2005 (Cayman S, Cayman S RHD) .
Removing accessories

Microsoft

Microsoft

Fig. 123: Reversing light switch

4. Pull off electric connector for reversing light switch.
Microsoft
Fig. 124: Mount for exhaust system

5. Remove mount for exhaust system from transmission.
Microsoft

1. Unscrew fastening screws -1 to 8- and pull out transmission to the rear. See Fig. 125.
REFITTING TRANSMISSION
Refitting transmission
Microsoft

1. Move transmission into position and screw in fastening screws -1 to 8- . See Fig. 126.

value 1 2
Microsoft

Fitting accessories

1. Fit mount for exhaust system on transmission.

1 2
Exhaust system Fastening screws between Tightening 45 (33
mount transmission housing mount torque ftlb.) Nm
Microsoft

Microsoft


value 1 2


value 1 2
mechanism and external shift mechanism torque ftlb.) Nm
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

(Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as
of MY 2005 (Cayman S, Cayman S RHD) .
34 35 27 REMOVING AND REFITTING TRANSMISSION - AS OF MY 2005

(BOXSTER, BOXSTER RHD)
TOOLS

PRELIMINARY WORK
Preliminary work
1. Remove engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

(Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Microsoft

2. Remove clutch slave cylinder. Refer to 30 30 19 Removing and installing clutch slave cylinder - 6-speed
transmission - as of MY 2005 (All Models) .

Microsoft

Microsoft


Microsoft

Microsoft


Microsoft

REFITTING TRANSMISSION
Microsoft


value 1 2
Hexagon-head bolt no. 2 in
figure (M12 x 100); with
washer
Transmission-engine Hexagon bolt No. 3 (M12 x 90) Tightening 85 (63
connection in illustration torque ftlb.) Nm
Transmission-engine Internal serration screw No. 4 Tightening 45 (33
connection (M10 x 35) in illustration torque ftlb.) Nm
Transmission-engine Tightening 45 (33
Nut No. 5 (M10) in illustration
connection torque ftlb) Nm
Transmission-engine Hexagon bolt No. 7 (M12 x 90) Tightening 85 (63
Microsoft
connection in illustration torque ftlb.) Nm


value 1 2
Microsoft

Fitting accessories


1 2
holder transmission housing holder torque ftlb.) Nm
2. Insert clutch slave cylinder into transmission opening and screw in fastening screw. Refer to 30 30 19
Microsoft

value 1 2

3. Push on electric connector for reversing light switch.
Fitting accessories
Microsoft


1 2
mount transmission housing mount torque ftlb.) Nm
Microsoft

Microsoft


value 1 2


value 1 2
mechanism and external shift mechanism torque ftlb.) Nm
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

(Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
34 35 37 DISASSEMBLING AND ASSEMBLING TRANSMISSION - AS OF MY

2005 (BOXSTER, BOXSTER RHD)
TOOLS

press-in device VW-tool 3235
taper roller bearing puller, commercially NR.119

Boxster manual available tool
transmission
engine support special tool P 9589
puller commercially v. a. g. 1582
available tool
grip piece commercially v. a. g.1582/2
available tool
engine and gear support VW-tool VW 540
PRELIMINARY WORK
Preliminary work
1. Remove transmission. --> 343519 Removing and installing transmission - section on "Removing"
Microsoft
Fig. 148: Transmission on assembly support

2. Tighten the transmission using engine support P 9589 or engine and gear support VW 540 at the assembly
support.
3. Drain transmission oil. --> 340155 Changing transmission oil - section on "Draining"
4. Remove sealing ring for drive shaft. Refer to 35 50 19 Removing and installing sealing ring for input shaft
- as of MY 2005 (Boxster, Boxster RHD) .
DISASSEMBLING TRANSMISSION
Removing transmission housing
Microsoft
Fig. 149: Overview of transmission housing

No. Designation Qty. Removal

Already removed during preliminary
1 Torx screw 3
work.
2 Guide sleeve 1
work.
3 O-ring 1
work.
4 Shaft seal 1
work.
5 Cup spring 1
Note the thickness for re-installation
6 Circlip 1
(must not be interchanged).
Pull out with puller v. a. g. 1582 and
7 Ball bearing 1
grip piece v. a. g.1582/2.
Note the thickness for re-installation
8 Circlip 1
(must not be interchanged).
9 Hexagon-head bolt 1
10 Tab washer 1
11 Reversing-light switch 1
12 O-ring 1
13 Torx screw 1
Removal instructions for transmission housing
Microsoft

Fig. 151: Driving out bearing

1. Drive ball bearing -7- out of the housing with taper roller bearing puller, Boxster manual transmission
NR.119. See Fig. 150.
Microsoft
Removing transmission cover
Fig. 152: Removing transmission cover


14 Torx screw 14
15 Transmission cover 1
16 Torx screw 1
17 Spacer 1
18 Torx screw 1
19 Spacer 1
20 Torx screw with collar 1
21 Switch interlock 1
22 Drive shaft 1
23 Output shaft 1
24 Relay shaft 1
Shift rod and shift fork for 3rd and
25 1
4th gear
26 Interior shift rod 1
Shift rod with shift fork for 1st, 2nd,
27 1
5th, and reverse gear
Removal instructions for transmission cover
Microsoft
Fig. 153: Gear set with gearshift

1. Pull out drive shaft -A- , output shaft -B- , deflection rod -C- , shift rods -D- and shift fork -E- together.
ASSEMBLING TRANSMISSION
Fitting transmission cover
Microsoft
Fig. 154: Removing transmission cover

No. Designation Qty. Fitting

--> Tightening torque: 25 (19 ftlb.)
14 Torx screw 14
Nm
Apply sealing material Loctite 574 to
15 Transmission cover 1 the contact surfaces and tighten Torx
screws -14- .
16 Torx screw 1
Nm
17 Spacer 1
18 Torx screw 1
Nm
19 Spacer 1
20 Torx screw with collar 1
Nm
21 Switch interlock 1
22 Drive shaft 1
23 Output shaft 1
24 Relay shaft 1
Shift rod and shift fork for 3rd and
25 1
4th gear
26 Interior shift rod 1
Only replace shift rod for 5th and
Shift rod with shift fork for 1st, 2nd,
27 1 reverse gear complete with shift fork
5th, and reverse gear
and driver.
Installation instructions for transmission cover
Microsoft
Fig. 155: Inserting shafts

1. Place drive shaft and output shaft together and insert into the transmission housing.
Microsoft
Fig. 156: Inserting interior shift rod

2. Insert relay shaft and interior shift rod.
- Shift into 3rd gear.
- Insert relay shaft.
- Place interior shift rod next to the guide bore of the bearing cover.
- Slide the shift finger into the driver of the relay shaft and swivel this carefully into the guide bore by turning
the interior shift rod.
3. Install switch interlock.
- Put the interlock slide into the center position.
- Shift into neutral.
- Insert switch interlock.
- Latch relay shaft into switch interlock.
- Secure switch interlock with Torx screw with collar.

Torx screw Tightening torque 25 (19 ftlb.) Nm
4. Insert and tighten screws for relay shaft.

5. Seal transmission cover with Loctite 574 and fit it. Ensure correct position of dowel sleeves in transmission
housing. See --> 34 37 37 Disassembling and assembling transmission housing - as of MY 2005 (Boxster,
Boxster RHD).
Fitting transmission housing
Microsoft


1 Torx screw 3 Fitted during subsequent work.
2 Guide sleeve 1 Fitted during subsequent work.
3 O-ring 1 Fitted during subsequent work.
4 Shaft seal 2 Fitted during subsequent work.
Insert with the smaller diameter
5 Cup spring 1
(curved side) towards the guide sleeve.
If ball bearing No. 7, the drive shaft or
the transmission housing is replaced,
calculate the thickness again. Refer to
6 Circlip 1
35 40 15 Adjusting the drive shaft -
as of MY 2005 (Boxster, Boxster
RHD) .
With the open side of the plastic cage
7 Ball bearing 1 pointing towards the guide sleeve,
press in with the press-in device 3235.
If ball bearing No. 7, the drive shaft or
the transmission housing is replaced,
calculate the thickness again. Refer to
8 Circlip 1
35 40 15 Adjusting the drive shaft -
as of MY 2005 (Boxster, Boxster
RHD) .
9 Hexagon-head bolt 1
Nm
10 Tab washer 1
Microsoft
11 Reversing-light switch 1 Insert in the correct position.

12 O-ring 1 Always replace, and lightly oil.
--> Tightening torque: 10 (7.5 ftlb.)
13 Torx screw 1
Nm
Installation instructions for transmission housing
Fig. 158: Pressing in ball bearing

1. Press in ball bearing for the drive shaft.
- Place thrust washer -A- of the press-in device 3235 onto the ball bearing. See Fig. 158.
- Position press-in device 3235 behind the toothing for the clutch plate on the drive shaft and pretension with
both screws -B- . The screws are supported in the two lowered areas of the thrust washer. See Fig. 158.
- Press in the ball bearing as far as it will go by alternately tightening the screws -B- (tighten only in 1/2 turns to
avoid tilting and thus damaging the ball bearing). See Fig. 158.
SUBSEQUENT WORK
Subsequent work
1. Install sealing ring for drive shaft. Refer to 35 50 19 Removing and installing sealing ring for input shaft -
Microsoft
as of MY 2005 (Boxster, Boxster RHD) .
2. Fill with transmission oil. --> 340155 Changing transmission oil - section on "Filling"
3. Remove transmission from assembly support.
4. Install transmission. --> 343519 Removing and installing transmission - section on "Installing"
34 37 37 DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING -

AS OF MY 2005 (BOXSTER, BOXSTER RHD)
TOOLS

pressure piece VW-tool 30-205
pressure piece VW-tool 3128
pressure piece VW-tool 40-202
threaded piece commercially 771/15

available tool
pressure piece commercially 9247/1
available tool
pull-in tool and puller commercially p 254
available tool

drive-in mandrel commercially vw 195
available tool
drive-in mandrel commercially vw 295

available tool
Microsoft
hook commercially vw 681

available tool
striker commercially vw 771

available tool
threaded piece commercially vw 771/15
available tool
bridge commercially vw 771/29

available tool
PRELIMINARY WORK
Preliminary work
Microsoft

support.
4. Disassemble the transmission. --> 343537 Disassembling and assembling transmission - section on
"Disassembling"
DISASSEMBLING TRANSMISSION HOUSING
Disassembling transmission housing
Microsoft

If the parts marked are replaced, re-adjustment is necessary (see Refer to 39 08 15 Adjusting the drive set - as
of MY 2005 (Boxster, Boxster RHD) ).

-1- Oil drain plug 1
-2- Torx screw 2
-3- Torx screw 1
-4- Tab washer 1
-5- Reversing-light switch 1
-6- O-ring 1
-7- Cap 1
Pull out using pressure piece 3128
-8- Taper roller bearing outer ring 1
and bridge vw 771/29.
-9- Adjusting shim S3 X Note the thickness for re-installation.
Press out using drive-in mandrel vw
-10- Needle-roller bearing 1
295 and pressure piece 40-202.
Remove with striker vw 771,
threaded piece 771/15 and a suitable
-11- Bushing 1
internal puller (e. g. Kukko 21/4,
23.5...30 mm).
-12- Torx screw 2
threaded piece vw 771/15 and a
-13- Lid 1
suitable internal puller (e. g. Kukko
21/3, 18.5...23.5 mm).
Microsoft
-14- Torx screw 1

-15- Lock (5th gear and reverse) 1
-16- O-ring 1
-17- Shaft seal 1 Pull out using hook vw 681.
Drive out using a suitable aluminum
Taper roller bearing outer ring
-18- 1 or copper mandrel (diameter of 6...8
(small)*
mm).
-19- Adjusting shim S2 X Note the thickness for re-installation
-20- Adapter 1
-21- Ball pin 1
-22- Sleeve 2
-23- Transmission housing 1
-24- Oil filler plug 1
-25- Shaft seal 1 Pull out using hook VW681.
Drive out using a suitable aluminum
Taper roller bearing outer ring
-26- 1 or copper mandrel (diameter of 6...8
(large)
mm).
-27- Adjusting shim S1 X Note the thickness for re-installation
-28- Cover for final drive 1
Instructions for disassembling transmission housing

Microsoft
Fig. 162: Pulling out bearing

1. Pull out taper roller bearing outer ring -8- using pressure piece 3128 and bridge vw 771/29. See Fig. 161.
Microsoft
Fig. 163: Needle-roller bearing for drive shaft

2. Press out needle-roller bearing for drive shaft -10- using drive-in mandrel vw 295 and pressure piece 40-
202. -A = Schraube M10x135- . See Fig. 161, Fig. 162.
ASSEMBLING TRANSMISSION HOUSING
Assembling transmission housing

If the parts marked are replaced, re-adjustment is necessary (Refer to 39 08 15 Adjusting the drive set - as of
MY 2005 (Boxster, Boxster RHD) ).

-1- Oil drain plug 1
Nm
-2- Torx screw 2
Nm
-3- Torx screw 1
Nm
-4- Tab washer 1
-5- Reversing-light switch 1
-6- O-ring 1 Always replace, lightly oil.
-7- Cap 1
-8- Taper roller bearing outer ring 1 Press in using a suitable pressure piece.
Microsoft
Calculate thickness again if necessary;

Adjusting shim S3 see Refer to 39 08 15 Adjusting the
-9- X
drive set - as of MY 2005 (Boxster,
Boxster RHD) .
Press into correct position (labelled
side facing the pressure piece) using
-10- Needle-roller bearing 1
pressure piece 40-202 and drive-in
mandrel vw 295; do not drive in!
Press in using pressure piece 9247/1
-11- Bushing 1
and pull-in tool and puller p 254.
-12- Torx screw 2
Nm
-13- Lid 1
-14- Torx screw 1
Nm
-15- Lock (5th gear and reverse) 1
-16- O-ring 1 Always replace.
Fill space between dust and sealing lips
with multipurpose grease. Drive into
-17- Shaft seal 1 correct position with drive-in mandrel
vw 195 (5.5 mm below top edge of
lid).
Taper roller bearing outer ring Press in using pressure piece 30-205
-18- 1
(small) and drive-in mandrel vw 295.
Adjusting shim S2 Calculate the thickness again if
-19- X
necessary.
-20- Adapter 1
-21- Ball pin 1
Nm
-22- Sleeve 2 Press into correct position.
-23- Transmission housing 1
-24- Oil filler plug 1
Nm
Fill space between dust and sealing lips
with multipurpose grease. Drive into
-25- Shaft seal 1 correct position with drive-in mandrel
vw 195 (5.5 mm below top edge of
lid).
Taper roller bearing outer ring Press in using pressure piece 30-205
-26- 1
(large) and drive-in mandrel vw 295.
Adjusting shim S1 Calculate the thickness again if
-27- X
necessary.
-28- Cover for final drive 1 Seal with Loctite 574.
Microsoft
Instructions for assembling transmission housing

Fig. 166: Measuring needle-roller bearing

1. Press in needle-roller bearing for drive shaft -10- using drive-in mandrel vw 295 and pressure piece 40-202
Microsoft
(do not drive in!). Measurement from top edge of rule to top edge of needle-roller bearing -a = 39.5 ± 0.3 mm- .
See Fig. 165, Fig. 166.
Fig. 167: Transmission vent rim offset

2. Rim offset of sleeve for transmission vent. -a = 27 ± 0.5 mm- . See Fig. 167.
3. Installation instructions for lock for 5th gear and reverse
- Insert spring -4- into plastic bushing -1- and press lightly to turn it anti-clockwise until the spring engages at
the base of the plastic part. See Fig. 168.
- Position the bushing -3- on the spring in such a way that the bent end of the spring is located in the groove
provided. See Fig. 168.
- Press the spring together with the bushing -3- , twist it on by turning it once anti-clockwise (to the left) until
the lug of the bushing -3- is located above the groove in the plastic bushing.
- Press the lug of the bushing -3- as far as it will go into the groove of the plastic bushing -1- .
- Turn the bushing -3- clockwise (to the right) and let it go.
Microsoft
Fig. 168: Lock assembly

- Bushing -3- pops into assembly end position.
1 - Plastic bushing
2 - O-ring
3 - Bushing with lock for 5th gear and reverse
4 - Spring
Microsoft
Fig. 169: Lock assembly

- The lug -A- of the bushing for 5th gear and reverse must always be positioned as far as it will go opposite the
groove -B- of the plastic bushing. See Fig. 169.
SUBSEQUENT WORK
Subsequent work
1. Assemble transmission. --> 343537 Disassembling and assembling transmission - section on

"Assembling"
34 55 37 DISASSEMBLING AND ASSEMBLING TRANSMISSION COVER - AS

OF MY 2005 (BOXSTER, BOXSTER RHD)
TOOLS

Microsoft
pressure piece VW-tool 3005
pressure pieces (4) commercially 9247/1

available tool
pull-in tool and puller commercially p 254
available tool

auxiliary piece commercially vw 295 a
available tool
commercially vw 407
available tool
commercially vw 420
available tool
commercially vw 423
available tool
striker commercially vw 771

available tool
threaded piece commercially vw 771/15
available tool
PRELIMINARY WORK
Microsoft
Preliminary work

support.
DISASSEMBLING TRANSMISSION COVER
Disassembling transmission cover
Microsoft
Fig. 171: Overview of transmission cover


1 Oil collection pan 1
2 Circlip 1
3 Washer 1
4 Reverse idler gear 1
5 Needle-roller bearing 2
6 Thrust washer 1
Drive out with a suitable internal puller
7 Retaining sleeve 1
and striker vw 771.
threaded piece vw 771/15,
8 Taper roller bearing outer ring 1
commercially available thread adapter
and a suitable internal puller.
9 Adjusting shim S4 X Note the thickness for re-installation.
10 Pressure plate 1
Drill a hole and remove washer with a
11 Rubber plate 1
sheetmetal screw.
Needle-roller bearing with plastic threaded piece vw 771/15 and a
12 1
sleeve suitable internal puller. Destroy the
plastic sleeve before fitting the puller.
13 Bushing 1 threaded piece vw 771/15 and a
suitable internal puller.
14 Shaft seal 1 Lever out.
Only remove if reversing gear axle is
15 Torx screw 1
replaced.
Microsoft
Undo Torx screws and remove

16 Transmission cover 1
transmission cover
Instructions for disassembling transmission cover

Fig. 173: Knocking out outer bearing ring

Microsoft
1. Remove retaining sleeve -7- . The retaining sleeve may be destroyed when it is removed as it does not need
to be refitted (it is only required during manufacture of the transmission). See Fig. 172.
2. Remove outer bearing ring -8- with a suitable internal puller and striker vw 771. See Fig. 172.
3. To remove the rubber plate -11- , turn sheetmetal screw in rubber plate if necessary and remove rubber plate
on sheetmetal screw. See Fig. 172.
4. Remove needle-roller bearing with plastic sleeve -12- using a suitable internal puller and striker vw 771. The
plastic sleeve must be destroyed in order to position the puller. See Fig. 172.
5. Remove bushing -13- with a suitable internal puller and striker vw 771. See Fig. 172.
ASSEMBLING TRANSMISSION COVER
Assembling transmission cover


Insert until the catch engages in the
1 Oil collection pan 1 bore of the transmission cover. The
collection pan must be facing upwards.
2 Circlip 1
3 Washer 1
4 Reverse idler gear 1
5 Needle-roller bearing 2
6 Thrust washer 1
Do not re-install! This part is only
7 Retaining sleeve 1
required during production.
Microsoft
Press in using a pressure piece 3005

8 Taper roller bearing outer ring 1
and a suitable plunger (e. g. vw 407 ).
Calculate the thickness again if
Adjusting shim S4 necessary Refer to 39 08 15 Adjusting
9 X
the drive set - as of MY 2005
(Boxster, Boxster RHD) .
10 Pressure plate 1
11 Rubber plate 1 Replace.
Always replace. Press into correct
position using auxiliary piece vw 295
Needle-roller bearing with plastic a and a suitable tubular piece (e. g. vw
12 1
sleeve 420 ). The large collar of the auxiliary
piece vw 295 a is facing the needle-
roller bearing.
Press in with pressure pieces (4)
13 Bushing 1 9247/1 and pull-in tool and puller p
254.
Fill the space between the dust and
sealing lips with multipurpose grease
14 Shaft seal 1
and drive in with a suitable tubular
piece (e. g. vw 423 ).
15 Torx screw 1 Tightening torque: 35 Nm (26 ftlb.)
If the transmission cover is replaced,
calculate the thickness of the adjusting
16 Transmission cover 1 shim S4 again --> Seal with Loctite
574.
Instructions for assembling transmission cover

Microsoft
Fig. 176: Tapping in sealing ring

1. Fill the shaft seal -14- between the dust and sealing lips with multipurpose grease and drive in with a suitable
tubular piece (e. g. vw 423 ). Observe the correct drive-in depth -a = 1 mm- . See Fig. 176.
NOTE:  The needle-roller bearing and plastic sleeve must always be replaced.
2. Press in bushing -13- as far as the stop with pressure pieces (4) 9247/1 and pull-in tool and puller p 254.
Microsoft
Fig. 177: Drive-in depth for needle-roller bearing

3. Press needle-roller bearing and plastic sleeve -12- into correct position using auxiliary piece vw 295 a and a
suitable tubular piece (e. g. vw 420 ). The large collar of the auxiliary piece vw 295 a is facing the needle-roller
bearing. Observe the correct drive-in depth -a = 216- . See Fig. 177.
Microsoft
Fig. 178: Pressing in outer bearing ring

4. Press in outer bearing ring -8- with a pressure piece 3005 and a suitable extension. See Fig. 175.
5. Fit transmission cover -16- . To do this, coat cover sealing surfaces lightly with Loctite 574 and screw in
Torx screws. See Fig. 175.

SUBSEQUENT WORK
Subsequent work
Microsoft

Manual Trans., Actuation, Housing PDF

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2007 Porsche Boxster S

TRANSMISSION Manual - Actuation, assembly housing

Manual - Actuation, assembly housing

34 01 35 CHECKING AND TOPPING UP TRANSMISSION OIL - AS OF MY

Designation Type Number Explanation

3. Place oil collection pan under the transmission.

CHECKING AND TOPPING UP TRANSMISSION OIL

Checking and topping up transmission oil

WARNING: Risk of scalding from hot oil

--> Let the oil cool down

--> Wear personal protective gear (goggles, gloves)

Fig. 1: Filler plug

1. Unscrew oil filler plug.

Fig. 2: Oil level in the transmission

Location Explanation Type Basic value Tolerance 1 Tolerance 2

Checking and topping up transmission oil

WARNING: Risk of scalding from hot oil

--> Let the oil cool down

--> Wear personal protective gear (goggles, gloves)

Fig. 3: Filler plug

1. Unscrew oil filler plug.

Fig. 4: Oil level in transmission

Location Explanation Type Basic value Tolerance 1 Tolerance 2

2. Lower the vehicle.

34 01 35 CHECKING AND TOPPING UP TRANSMISSION OIL - AS OF MY

Designation Type Number Explanation

3. Place oil collection pan under the transmission.

CHECKING AND TOPPING UP TRANSMISSION OIL

Checking and topping up transmission oil

WARNING: Risk of scalding from hot oil

--> Let the oil cool down

--> Wear personal protective gear (goggles, gloves)

Fig. 5: Filler plug

1. Unscrew oil filler plug.

Fig. 6: Oil level in the transmission

Location Explanation Type Basic value Tolerance 1 Tolerance 2

2. Lower the vehicle.

34 01 55 CHANGING TRANSMISSION OIL - AS OF MY 2005 (BOXSTER S,

Location Explanation Type Basic value Tolerance 1 Tolerance 2

3. Place oil collection pan under the transmission.

DRAINING TRANSMISSION OIL

Draining transmission oil

CAUTION: Transmission cannot be filled, or only insufficiently with ATF.

--> Do not start engine

--> Do not tow vehicle

WARNING: Risk of scalding from hot oil

--> Let the oil cool down

--> Wear personal protective gear (goggles, gloves)

Fig. 7: Filler plug

1. Unscrew oil filler plug.

Fig. 8: Oil drain plug

2. Unscrew oil drain plug and drain transmission oil.

REFILLING TRANSMISSION OIL

Filling in transmission oil

CAUTION: Transmission cannot be filled, or only insufficiently with ATF.

--> Do not start engine

--> Do not tow vehicle

Location Explanation Type Basic Tolerance Tolerance

2. Filling capacity 2.8 litersFill with transmission oil.

3. Clean oil filler plug and screw in with a new seal.

Location Explanation Type Basic value Tolerance 1 Tolerance 2

2. Lower the vehicle.

34 01 55 CHANGING TRANSMISSION OIL - AS OF MY 2005 (BOXSTER,