GBOX Transmission-996/997 2nd GEAR TIP

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GBOX, INC.

455 YOUNG CT. UNIT 1

ERIE, CO.  80516

303-440-8899

GBOXINC@YAHOO.COM

Hours:

Mon-Fri > 8am - 5pm MTN.

Sat-Sun > By Appointment.

996/997 2nd GEAR TECH TIP

996 shift fork

Proper adjustment of the 1st/2nd shift fork and operating sleeve is necessary to prevent 2nd gear pop-out. There is no adjustment on the shift fork itself (it's dowel-pinned in place on the rod); the adjustment is made by shimming the 4th gear on the pinion shaft, which changes the positioning of the 2nd gear on the stack. Porsche makes fourteen different thicknesses of shim for this purpose.

996 gear shims

Several factors can affect the correct adjustment (including the thickness of the bearing retainer shim), and must be taken into account when setting up the gear stack. Because the gear stack must be pressed apart to change the 4th gear shim, proper measurements need to be taken to assure correct stack height.

If the distance between 2nd gear and the 1st/2nd operating sleeve is incorrect, the operating sleeve will not completely engage the dog ring on 2nd gear. Incomplete engagement will cause the '2nd gear pop-out' problem common to these gearboxes. Incomplete engagement and the resulting 'pop-out' will ruin the 2nd gear dog ring and require 2nd gear replacement.