Is this true? 6 speed manual boxes have weak 2nd gears/synchro?

[911hillclimber]

Just read a few posts about the above and a user who has has 3 gearboxes fail on his 3.2S.
Failures are the gear does not detent fully so can pop-out of position to it won't take 2nd speed (cold oil)

I thought I knew pretty much all the Boxster's issues, but first time I've read this.
Quick look at Google and sure enough reports on this.

My bx is 85K miles old now, oil changed about 20K miles ago, original clutch.

All is great, but I don't hurry the gearbox esp when cold.

 

[Motorhead]

Me neither Graham, although 2nd gear baulking does appear to be reported even on the later cars, 718s included. I’ve a feeling that there could be double-synchro on that gear … not sure?

I recall that there was an issue with 3rd gear on the 981 GT4 when Getrag replaced a splined gear attachment for a welded one, requiring a transmission replacement [I assume they reverted to the splined attachment?].

The 6-speeder has been in production for a long time and I would imagine that there have been some revisions along the way, but with thousands of Caymans and Boxsters out there some failures are inevitable, no doubt amplified by internet reporting.

Jeff

 

[911hillclimber]

Interesting!
There is indeed a pop-out issues POTENTIAL on 986 boxes and seems some Caymans have up to 2010 issues too.
I only say this because of:
There is a UK specialist who does all this engineering with mods to correct the 2nd gear jumping out of position (detent) when gently on/off the light throttle.

About £3000 to fix on a loose box.

No idea how numerous this issue is, but another reason to scrap an early car looming....

I think the 986 (maybe the 987) box is an AUDI A4 box which may be an alternative fix, but would have thought an A4 would be in the same situation?

 

[Motorhead]

Yes Graham, I believe that the 5-speed G86 Getrag manual transmission was used on an Audi. The chap who developed the 986 Booster reckoned that Porsche may well have used it in conjunction with the 5-valve I-4 1.8T for early prototypes.

According to Paul Frère’s excellent book Porsche Boxster Story, the 6-speed was a development of this unit and was used initially on the 3.2-litre Boxster S. The G87 5-speed used on the 987-series cars was a development of the previous unit but with triple-cone synchro on first gear and a double-cone device on second gear, and 6-speed units used in MY2005 3.2-litre Boxsters had a higher torque capacity with triple-cone synchro on first and second gears and double-cone synchro on the four upper gears.

I would imagine that aside from gear and final drive ratio changes, the current transmission is very similar to that introduced in 2005, although improvements could have been made to increase its torque capacity to make it suitable for the 718 GT4/Spyder/GTS 4.0-litre cars. It now must be at or near its reliable torque limit, and isn’t an option on the RS cars … presumably in part for this reason?

Jeff