25 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHReplacing 1st gear
Reported or suspected cause
widespread problem
Reported cause
No successful repair reported for this finding.
1
Identified cause
0
Suspected cause
0
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Read evidence and context
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Discussions that report identifying a cause
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Reported cause
Like Porschetech3 says, the 2nd gear popout issue was a widespread problem.
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Suggestion
I can't speak from experience, but I am about to do a similar project (I need to go one step further, pulling 2nd gear to replace the 2nd gear synchros).
Leading evidence: 'widespread problem' (1 discussions report identifying this cause; no attributable repair resolution). Across 1 matching discussions, the most frequently mentioned possible cause is 'widespread problem' (1 discussions; 1 report identifying it and 0 suggest it). The most frequently discussed action is 'Replace 2nd gear synchros)' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Suggestion
I can't speak from experience, but I am about to do a similar project (I need to go one step further, pulling 2nd gear to replace the 2nd gear synchros).
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Suggestion
Although difficult, they were able to press the gears off, replace the bearing, then heat the gears to re shrink onto the counter shaft."
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
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Suggestion
Replacing the pinion bearing "while your in there" for preventative maintenance adds a LOT of extra cost and labor to a relative inexpensive 2nd gear repair.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Suggestion
Drain and drop the transmission, put it up on end, remove the housing retaining bolts, pull off the housing, use a 8" gear puller to pull the gear stack off.
These are separate views of the same evidence. Frequency alone does not establish a fix, and these counts must not be added together.
Replace 2nd gear synchros)
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
I can't speak from experience, but I am about to do a similar project (I need to go one step further, pulling 2nd gear to replace the 2nd gear synchros).
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Replacing the pinion bearing "while your in there" for preventative maintenance adds a LOT of extra cost and labor to a relative inexpensive 2nd gear repair.
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Drain and drop the transmission, put it up on end, remove the housing retaining bolts, pull off the housing, use a 8" gear puller to pull the gear stack off.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
25 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261026T225432Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
So, I've owned my car for over a year and a half so far and ever since I bought it it's had a chipped 1st gear. I've recently gotten into autocross and it's really been a hindrance grannying it in 1st gear then immediately shifting into 2nd. I'm planning on changing out the clutch over the winter and figured what the hell let's dig myself into a deeper hole and change out this first gear. My only problem is I don't know where to buy a new gear set or just 1st gear in general. Anyone have any experience with this? A link to one would be amazing..
I can't speak from experience, but I am about to do a similar project (I need to go one step further, pulling 2nd gear to replace the 2nd gear synchros). The advice I've gotten (from people much more experienced than me) is that it isn't a huge project if you are mechanically inclined. Drain and drop the transmission, put it up on end, remove the housing retaining bolts, pull off the housing, use a 8" gear puller to pull the gear stack off. Heat the replacement gears and drop them on. I'm sure I've dramatically oversimplified, since I haven't actually done it, but that is the gist of it. The one thing I wonder about (for my job) is whether I need to take off the shift fork by driving out the roll pin before pressing off the gear stack.
This is what happens to the gears those guys weld new teeth onto. I would suggest getting a new mainshaft kit, especially if the car is being raced. One can't get 1st gear by itself, so it's a new mainshaft with 1&2. Expect about $2k for the mainshaft and another $1-2k in labor and other needed parts.
For a 996 Carrera gearbox a 40 ton press is required to get the gears off. They are press fit, and not splined like the GT3 gears. No 8" puller will get those gears off.
I haven't tried it, and you've done lots of them, so I guess that leaves it pretty clear who people should listen to.
That being said, this guy did it with a puller:
https://rennlist.com/forums/996-foru...ement-diy.html
From his write up...
"This is as far as I was able to break down the transmission myself. Gears 3-6 on this shaft take over 30 T of force to remove, so I brought it to a local automotive machine shop with the new pinion bearing. Although difficult, they were able to press the gears off, replace the bearing, then heat the gears to re shrink onto the counter shaft."
Thanks for the clarification.
I thought the OP was trying to get to first (and I'm trying to get to the second gear synchros). If I understood the diagrams, those are on the end that can be pressed off with a puller. No?
Working from the nose/front of the transmission, doesn't it go R, 1, 2, 5, 6, 3, 4? Pulling off the first two gears on the stack would pull R and 1, wouldn't it?
That's correct, the "loose" gear R 1 2, and associated syncro's can be removed with an 8" puller
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The OP has a chipped gear on 1st (large drive teeth) that has probably damaged the "fixed" 1st gear that is part of the input shaft and cannot be removed, the complete input shaft will need to be replaced. To replace the input shaft, the "loose" gears 5-6 3-4 and associated synco's and input bearing will have to be pressed off. While it doesn't require 40 tons to remove these a press is require due to very long reach.
If the "fixed" 5-6 3-4 gears need to come off the output shaft to be replaced OR to get to the pinion output bearing THAT'S where the 40 ton press is needed. Once these gears are pressed off, they go back on with a little less force and can only be removed 4 times as the fit will be too loose. Anytime the gears are pressed off a "R" should be stamped at the serial number indication how many times they have been off.
Sure, if you are only going to do half the job. The pinion bearing is the failure point on these gearboxes. Even if you weld on a new set of dog teeth I would consider it a fool's errand to go into the thing and leave the case bearings undone. But to each their own. If you do go the welded dog replacement route, use California Motorsports. They do better work than the other guys.
I disagree that the pinion bearing is the main failure of G96 gear box , it is second to the second gear pop-out and associated damaged syncro teeth. I have seen WAY more 2nd gear damage than pinion bearing failures.
Replacing the pinion bearing "while your in there" for preventative maintenance adds a LOT of extra cost and labor to a relative inexpensive 2nd gear repair.
Plus pressing fixed gears 5-6 3-4 off to get to the pinion bearing can only be done 4 times.Then throw the trans away.
not necessarily true. A trans with that many miles probably did not spend much time in 1st and 2nd gear. More likely lots of Interstate miles with very little gear shifts. This is very gentle duty for a trans.
At 141K mi I would be even more concerned about that pinion bearing. We've seen them frequently fail in the 75-80k mi range. Even if it was rebuilt earlier in it's life, it's likely due again. Plus you have no idea how 1-2 are condition-wise because you can't drive it. It's totally a pig and a poke. Like Porschetech3 says, the 2nd gear popout issue was a widespread problem.
My car is at 79K miles right now and so is the transmission. What are some signs that the pinion bearing is starting to go? Or is it one of those things that just happen? Also my transmission has never popped out of 2nd, it's only once ever felt like it was going to pop out of 1st, but I feel like that was because of the chip in 1st gear.
Ok, here’s another one for slightly more $$. Same supplier, but less miles than your current trans.
https://rover.ebay.com/rover/0/0/0?m...2F282953685889
