Instructions For Disassembly And Assembly (Transmission G86): Assembly

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.

Check synchronizing rings for wear. Refer to DISASSEMBLING AND ASSEMBLING THE INPUT SHAFT (TRANSMISSION G86) .
Insert the spring into the loose gear wheel so that the angled end engages in the hole.
Install selector sleeves in correct position. The slanted side is facing the reverse-gear loose gear wheel in the case of the selector sleeve for 5th and reverse gear. The slanted side is facing the 2nd-gear loose gear wheel in the case of the selector sleeve for 1st and 2nd gear.
Determine the snap ring for the tapered roller bearing. To do this, determine the thickest ring which can still be used.

Fig 1: Determining Correct Snap Ring For Tapered Roller Bearing
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Determine the snap rings of the synchronizing elements and of the 3rd and 4th gears in exactly the same way.
Arrangement of the snap rings:

Fig 2: Identifying Snap Ring Positions

Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE:

The size of snap rings 1, 2, 4, 5 and 7 must be determined again. The snap rings 3 and 6 always have the same thickness. Snap ring 3 is 2.5 mm and snap ring 6 is 2.0 mm thick. See Fig 2 .