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Discussion summary
YOUR RESEARCHMy First 911 - 1999 996 C2 (With Pictures)
Leading reported evidence
Install cluster into the transmission case
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
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 performed work without a confirmed outcome
1
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Performed · outcome unconfirmed · Original poster
Once the cluster was assembled, I fitted the cluster into the transmission case.
Leading evidence: 'Install cluster into the transmission case' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Inspect clutch and ims bearing' (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.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
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 performed work without a confirmed outcome
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.
Performed · outcome unconfirmed · Original poster
Cover is installed here, and the transmission is ready for installation in the car.
Install motorad 160 f thermostat while i was in there
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
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 performed work without a confirmed outcome
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Performed · outcome unconfirmed · Original poster
New Pierburg water pump, figured it was a good time to replace.<br/><br/>Also installed a MotoRad 160 F thermostat while I was in there.
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 performed work without a confirmed outcome
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Performed · outcome unconfirmed · Original poster
I have ran the fans on low speed for 10+ minutes, they were little warm but the temperature was steady, i dont think ill have any issues.
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 performed work without a confirmed outcome
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.
Performed · outcome unconfirmed · Original poster
I used Motul 300 gear oil after reading a few threads with positive reviews and recommend it to anyone with a 996.
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.
41 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: 20261026T191851Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Hi All,
I purchased a my first 911 a few months ago, its a 1999 996, Carrera 2, 115,000 km. Its been a blast to drive so far, and a nice upgrade from my previous 2000 Boxster S.
Modifications:
Aero Kit - Does anyone know what kind of front bumper is on the car?
Champion RG5 19" wheels
H&R lowering springs
PSE Exhaust
K&N Intake
The car is currently stored for the winter, and I am performing some maintenance work. This forum has been a great resource for information on these cars.
Here are some pictures:
Some other work ongoing this winter:
Ramps i built to jack from the center front and rear. Very useful in getting to the rear beam to avoid jacing from the engine case.
New strut mount and new sway bar end link install.
Assembled - some fresh paint
Some new rubber - Michelin Pilot Supersports (235 front/295 rear!)
Custom low speed radiator fan resistors. Old ones were burnt out. Made these up for 10% of the cost of new ones.
Decided to add switches for low and high speed radiator fans. I like being able to switch them on early when idling in the warmer months.
New Pierburg water pump, figured it was a good time to replace.<br/><br/>Also installed a MotoRad 160 F thermostat while I was in there.
I've installed a ECS magnetic drain plug and 3 filters to monitor any debris the engine might be producing. With the weak Canadian dollar its not a good time to purchase the IMS retrofit kit.
I also just picked up a motive pressure bleeder, i plan to flush the system with Motul RBF600 fluid before spring.
Great winter projects on a beautiful car. Couldn't help but notice the tires are 19s. Have you run with 18s previously? Just wondering how handling is affected by the larger size.
I believe it is different than the techart bumper, a friend of mine has that one and mine is a little less aggressive looking. I have done some searching and can't seem to find any information on it!
Pulled the transmission to inspect the clutch and IMS bearing.
Clutch and pressure plate need replacing.
Made up a cam lock tool for the 5 chain motor, had it cut with a water jet.
IMS bearing is in great shape! Spins freely, and no play. I decided to keep the bearing and remove the seal. There was no grease left inside, just motor oil.
Congrats, nice looking car. Unique combination of aero, wheels, and color. Love the subtle rear wing, do you know the manufacturer or part number? Also, is that pressure plate as sad looking in person as it is in the pic? How did it drive just before you pulled it apart?
I am not entirely sure the manufacturer of both the rear wing or the front bumper, to be honest I haven't even seen any others with that bumper.
So in the pic I have the clutch disc layed on top of the PP, the disc is worn right to the rivits on the PP side and the PP was very rough. interestingly it was fine to drive, maybe a little bit of chatter every few starts, but I didn't expect it to be that bad when taking it apart.
Thank you for the replys everyone.
Next and final job is to look into the pinion bearing and second gear of the transmission. This will take some time as I will need to make up some tools. I will update as I make progress.
Nice work so far...!
Tell us more about the Custom Low Fan Resisters you built...?
Specs... function... feedback... costs... more pics...?
(So far I found the resistors you used... they look a little different but thats the part number...
http://www.mouser.com/ProductDetail/...content=Ohmite
)
Nice to see a fellow Newfie with this awesome P-car. Yea, I'm also from Newfoundland but now living in BC. Have a really good friend in St. John's that also has a 996.
Those are the correct ones, I think the picture might be a generic.
Specs: 75W, 0.50 ohm, 5% tolerance
I have ran the fans on low speed for 10+ minutes, they were little warm but the temperature was steady, i dont think ill have any issues.
I would recommend getting the 100W resistors if you plan to go this route. Theoretically these resistors will dissipate close to 75W during normal operation.
Yea, I was very surprised to see that you are in Newfoundland. Not many P-cars there, especially 996s. My friend has a 2004 996, I think the colour is called meridian metallic - one of those colours that changes with the light. He is also a real Porsche enthusiast, not sure if he is here on RL tho.
Good luck with your car. Looks like you enjoy working on it. I guess you have another 2 or 3 months to finish your projects before the driving season starts there.
Oh yeah, i know there is a small group that get together for a run every so often, I haven't been able to find anything out about it though.
I really enjoy working on the car, hopefully we can have cars out by the end of April here!
[QUOTE=joe-1972;13004758]Nice work so far...!
Nice? It's the best 1st post I have ever seen! Great car being made better, good pic's, PRE-SEARCHED!!
This thread should be made a sticky for initial post.
Welcome Nick, 2016 MVP !
Spent some time this morning continuing disassembling of the transmission.
First step was to remove the shift rods. Each rod has one or two coiled spring pins that need to be hammered out. After that, the bolt at the base of the shift rod can be removed along with the ball and spring. This will allow the rod to be pulled out through the fork, then the fork can be removed.
All bolts that hold the gear cluster against the transmission housing are then exposed, so they can be removed. I used some heat where the pinion bearing fits into the housing to help while prying.
Here is the gear cluster removed.
The pinion bearing is the large bearing above the pinion gear, on the shaft to the right.
Transmission housing with the cluster removed.
I then went ahead and removed the differential for inspection. both axle flanges had to be removed for this which involved just using a couple of the axle bolts to push them off the differential splines.
The side cover was then removed by removing the 12 bolts.
Check out the pitting on the spider gears.. Ouch! I heard that this was common but never expected it to be this bad. I do not believe this is the cause of the noise I was hearing as when driving straight with both wheels rotating at the same speed, these gears should not be spinning against eachother. Seems like the pitting is only on the output spider gears.
Next step is to pick up the output shaft tool I had made up for pressing the output gears off and look into finding a shop willing to help me press some gears!
I recieved my EPS clutch kit in the mail as well. See the following thread for information on that kit:
https://rennlist.com/forums/996-foru...l#post13060994
Ok - 3 thoughts
1 - holy crap that's cool
2 - what do you do that you have this kind of ability and skill?
3 - haven't you heard the Porsche transmissions are made of exotic components that can not be repaired by mere mortals (hope I spelled mere right)
Transmission gear cluster breakdown continued yesterday - pulled the first and second gear assemblies off the output shaft. Here are some pictures.
Pulling first gear.
both first and second removed.
Here is the damage to the second gear dog ring and shift sleeve. The first picture shows the wear in the dog teeth on second gear and the second picture shows the wear on the shift sleeve on the second gear side. The following pictures show the wear on the first gear side of the sleeve, and what the dog teeth should look like on second gear. (Picture is first gear dog teeth - in excellent condition)
The next step is to remove the mainshaft bearing. This is going to be challenging as I dont have the VW402 tool used to press it off. Might need to get this tool manufactured locally..
So I had some difficulty finding a shop to press off the gears off the output shaft for a new pinion bearing, but after a couple of weeks of waiting, the new bearing has been installed.
Then it was time to press the cluster back together. Here is a picture of pressing the input shaft bearing onto to the input shafts which keeps the shafts together.
The rest of the cluster was put together simply by heating each press fit part in the oven for 20 minutes at 400 F, and dropping on in the same order as removed. The gears and components stacked perfectly and the top circlip went on without any issues.
Picture below shows the 1-2 gear shift sleeve and second gear stacked on the shaft.
Once the cluster was assembled, I fitted the cluster into the transmission case. This went pretty smoothly as well. Just heated the case with a torch and cooled the cluster in the freezer.
Next step was installing the shift forks and the differential.
And then installing the cover. This was the most difficult part of the job, it was tough to align the shift rods into the corresponding bearings in the cover.
Cover is installed here, and the transmission is ready for installation in the car.
Transmission install went relatively smooth, although it was very difficult to install the clutch slave cylinder.
And here is the car ready to go!
I have driven it for around 30 minutes and so far everything seems great. No noise and the car shifts incredibly. I used Motul 300 gear oil after reading a few threads with positive reviews and recommend it to anyone with a 996. The transmission shifts much smoother than it ever did. my reverse lights are not working so I believe my reverse switch failed at some point so I have a new one ordered. The EPS clutch kit is great so far, grabs nicely and the pedal feel is good.
Thanks for viewing!
