Gearbox needs rebuilding, what other preventitive work shoudl I do?

As documented in a few previous posts I�m having my transmission out and it needs stripping for a repair. Whilst having all this work, I am considering what other preventative maintenance would be worth having done. My car is a 2004 40th with 41k miles, I was thinking: 1. 2nd gear syncro (car occasionally jumps out of 2nd when cold, and they need to strip the box anyway) 2. LN IMS and new RMS 3. New AOS, (no issues at present but it is a pretty cheap part and easy to install whilst the rest of the work is boing done) 4. Possibly a new clutch depending on wear Is there anything else worth considering?, I plan to keep the car and whilst I don�t want to spend the equivalent of the Ecuadorian GDP, I�d like to cross a few things off the �911 worry list� Thanks Ross

Quotes source post: 9848919

2nd gear pop out is not a synchro problem per se. It is the dog clutch (teeth) of the 2nd gear set that is bad. Arising from various circumstances these can get rounded off and after a while they no longer can grip well and slip. For slip in this case the dog clutch teeth disengage and the transmission pops out of gear. Every time it does this the wear just gets worse and at some point the gear pops out of gear with just a bit of load. 'course if the 2nd gear synchro (or any gear's synchro) shows signs of wear/tear it should get replaced. This is true of any hardware in the gear box. Once the tranny case is open and the guts apart there's no reason not to replace/renew whatever is worn or damaged. But there is no need to overdo it either. A good tranny shop, a good tech, will know what to replace or leave alone. The same applies to the clutch and assorted/related hardware. If the tech believes the clutch is more worn out than not then replace it. Now I've been told the clutch wear is not linear thus if the clutch is worn say 25% at 40K miles it may not probably will not be worn out at even 160K miles. For the LN IMS bearing question, some owners feel this is worth the cost even if the tranny isn't coming out to be rebuilt. And some elect to leave things alone and roll the dice. Your call. Normally I'd advise if the RMS is oil tight to leave it be but since it is easily replaced with the tranny out if it gives you peace of mind...replace it. IIRC the AOS part cost is not very much. Labor is the biggie. If you can save enough money on labor to make it worth your while, have it replaced, even if it is not showing any signs of distress. Odds are it will eventually (maybe not for another 40K miles or more though, but they have been known to act up with fewer miles). The CV boots should be inspected and if cracked/split replaced, after the half-shaft CV bearings are cleaned/inspected and found to be good. (My 02 Boxster had this service done at around 240K miles and the tech found the bearings in good shape. A clean, repack with new boots and they're back in service with another 20K miles on them heading towards another 240K miles...) Sincerely, Macster.