[qwk_croc]

Back in July I was on my way home from the shop, down shifted into 2nd gear coming into the neighborhood and something let loose in the trans. Started making lots of horrible nosies.

When I bought the car (2008 Cayman) back in February I didn't notice any noise from 2nd gear (it was cold and didn't drive much with the windows down). I drove at the HPDC at Summit Point in March and got some comments about my car making some weird noise in 2nd gear, but it was only happening under acceleration. No one really knew what to make of the noise. Over time, I noticed it more driving past walls to reflect the trans noise.

Fast forward to today...I knew the trans was broken (I've got the 5-speed VW built trans). Instead of rebuilding it, I found a used one with relatively low mileage to swap it with. It was a bit of a risk, but turned out well. The Croc is back on the road!

I should point out that the car did have one over-rev to the 6th bucket early in it's life that I believe caused this damage. The leak-down test came back near perfect, so the engine is good.

So my question to the community is: Does anyone have experience/advice/guidance deconstructing a 5-speed from the 987.1? I have no intention of rebuilding it. Maybe I'll turn it into a coffee table or lamp. Here is my progress so far:

1. Remove tail section


2. Attempt at removing the Diff. The cover runs into the half-shaft flange. Not sure how to remove that. Use a rod/pull hammer?


3. Tail section removed


4. 2nd gear destruction!


5. Gear selector removed.


6. We believe the bearing needs to be removed and then the gear sets should slide out? Need to find a bearing splitter.

[smdubovsky]

Dang! When was the last time you changed the fluid? Should have noticed some of those bits coming out..

[qwk_croc]

Nothing came out in the gear oil the first time I changed it. Wasn't even shiny. There were plenty of chunks after it broke.

[BillC]

Originally Posted by qwk_croc

2. Attempt at removing the Diff. The cover runs into the half-shaft flange. Not sure how to remove that. Use a rod/pull hammer?

The axles are pressed into the diff. The usual way of getting them out is to put steel plates between the axle flange and the case, and then run two CV bolts through the axle flange to the plates -- tighten the bolts evenly, and you'll walk the axle out. The plates are to keep the bolts from damaging the case. However, since you have the trans out of the car, and if you don't care about damaging the side plate or case, you could use a couple of large pry bars to pop the axles out.

[qwk_croc]

Borrowed a slide hammer from Autozone to get the stub axles out. Once both sides were out, the diff slide out. More gear teeth were collected by the magnet in this area. I'll pick up a bearing splitter over the weekend to get the output shaft bearing out, which should help in releasing both shafts. I think there are some ring pings i need to release also.

[smdubovsky]

I've never been in a cayman trans but I don't think you should have to take off that rightmost tapered bearing and slide the gears off the stack. It should pull out as one (assembled) unit.

The pinion bearing should be a similar looking tapered bearing facing the other way from the one you see and its housing is larger than the pinion itself as the pinion typ needs to go out in the right direction as shown in your last pic. There isn't enough room to slide the shaft left into the diff housing to get it clear of the bearings before being able to swing it out. Is there some bolt or pin holding that in?

[qwk_croc]

Found some info that might help. Does anyone have access to these tools?

VAG1582 and VAG1582/2

These would help remove the input shaft bearing and would release the input and outputs shafts.