Porsche ZF PDK gear set removal, front case removal 

Do you have any external leaks? At the seals between each section, like the double seal on the long half shaft, there is a weep hole on the outside that shows which of the seals is leaking. If nothing external it's probably the seals in the shift rod actuator like you say. Which direction is the fluid going? Clutch section to gear section?

no external leaks. clutch oil goes into gear oil chamber. If it opposite like gear oil goes to clutch chamber. might be leaks from drive axles shaft seal, input shaft seal or somekind of seals or Oring where hydraulic pressure is not appliled. I'm looking for how to make sure the leaking from shift rod shaft seals. I was wondering If I could get the seals for shift rods.@@jeffrichardsoncardiy

If there are no external leaks, from what I've seen the only place it could go from the clutch chamber to the gear chamber is via those shift actuator seals. The seals aren't available as spares, so my best advice would be to remove them and go to a hydraulic seal shop and see if it's something that can be bought off the shelf.

Thanks! I'll try to remove the shift rod actuator seals first.

Yes but for one thing from what I understand. The gearing ratio between the output shaft and pinion shaft is different in the 2.7 transmission so it has slightly shorter gearing across the entire range. Everything else is identical.

Do you think it's possible to swap parts between gearboxes to manipulate gearing given the amount of shared parts? For example the manual box has a 3.89 final drive vs the 3.62 found in all the PDK gearboxes.

Freddy, I didn't pull this out of the transmission due to it being beyond what I could do in my shed. Without a manual or other guidance I really had little idea how to tackle it. I would try and find a workshop that deals in ZF transmissions, as I suspect the setup is similar to what is used in other ZF units. I've rebuilt a ZF auto before that was an AWD version from an Audi that had the same internal pinion shaft/diff setup. I didn't remove the pinion shaft, but the setup was similar, which is why I think a workshop like this might be able to at least guide you in the right direction if you want to do yourself.

Thank you for your swift response Jeff , I also wanna inquire, can a 981 Boxster cayman S gearbox be fitted on the Boxster cayman base model 2.7l? What are major differences btw the Boxster S gearbox and the base model. And lastly even if there’s a possibility, do you advise?

@@Freddy-cx7iz It's going to fit but not work. The output shaft to pinion shaft ratio is different on the base model transmissions. This would have rev matching etc not work correctly and I would suspect a raft of other issues. It might be possible to code the car in PIWIS to say that transmission type is fitted but I don't know of anyone who has attempted this. If replacing the transmission from what I understand you don't have much choice but to find one from a base model Cayman or Boxster.

Thank you so much Jeff. If I have any further questions, I will refer back to you

Hello Jeff did you find anyone that could help in removing the pinion shaft

There are some you can get access to easily, but most you will only get access to by fully disassembling the gear set. Not something I have the knowledge or workshop to do.

@@jeffrichardsoncardiy I see. However I think the most wear and tear part of the manual/ PDK gear box is the synchromesh. Finally, they need to be replaced. ZF does not provide parts for that.

It might be on other manual gearboxes, but I've never heard of this issue in the PDK. It might be a problem as the cars age, but there are many other wear items that seem to fail earlier like the clutch pack.

@@jeffrichardsoncardiy Thanks for the info. Which parts wear first in PDK?