Porsche Boxster Roof Transmission and Arm Repair - How to Fix, Setup and Adjust your Boxster roof

We replace the broken gears in the roof transmission and the plastic rod caps before aligning it.
Don’t buy the metal gears!! They bound up and didn’t work.
Parts used:
Replacement gear right - amzn.to/3pMw7p9
Replacement gear left - amzn.to/3CAZkuM
Rod end caps - amzn.to/3PUsOXR
987 plastic gearbox covers - Ebay ebay.us/ZtH6FD part number 98756158900
Grease - on the track we used amzn.to/3AR3KfW
The Eddy’s Garage is just a home garage maintaining and modifying our cars and some friends cars.
Check out the playlists for our different cars
Audi S3 8V Sportback • Audi S3 8V
Porsche Boxster S 986 • Porsche Boxster S 986
Jeep Grand Cherokee Diesel • Jeep Grand Cherokee WK2
Alfa Romeo Giulietta • Alfa Romeo Giulietta
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Disclaimers
We will take no responsibility for any errors in our videos causing damage to person or property. These videos are for entertainment purposes only and you should always seek professional advice before doing any work on your car.
This video description may contains links to different companies. Some are just the parts used and some that have helped us out with discounts.
I have been working on my own cars for many years but I am a self taught Do It Yourself, shade tree mechanic. I am NOT a professional mechanic. I do not have any formal automotive training.
The Eddy’s Garage assumes no liability for anything you choose to do to your car, before, or after watching one of our videos or utilising products or the content from this channel.
All DIY repairs or modifications have a level of inherent risk to person and property (your car). Anything you do to your car are done so at your own risk.

[@richardpope2114]

Excellent work , clear and concise step by step , filmed well and good sound and clear narration of each step
repaired well using basic hand tools
Spot on

[@TheEddysGarage]

Thanks mate. I try to make videos that I want to watch.

[@patrickjones503]

Great video. As a 987.2 owner I feel your frustration. I’ve had the exact same issue. Glad you didn’t edit out your difficult sequences. Again..great job.

[@TheEddysGarage]

Thanks 👍

[@dasquishy9613]

The replacements are not metal because the gear is intended as an intentional fail point to not mess the motor up for the top

[@TheEddysGarage]

Yes indeed

[@2minutes2switch47]

Many thanks for this informative video.

[@TheEddysGarage]

No problem. Be sure to like it so other people can find it easily

[@carlosrangel1045]

Thanks for doing this, really helpful. I just recently replaced my gears for the metals ones, they work just fine. I had an issue with the ball sockets I need to replace a hex that went missing!
To remove those ball sockets use the Porsche tool kit there’s a long screw driver with a red top that’s the tool for that. They pop right on and off

[@IsraelSocial]

Thanks

[@TheEddysGarage]

You are welcome. Throw it a like so others can find it easily when looking for help on their Boxster.

[@PaulCuenin]

Thanks for sharing

[@hawkinsjd11]

I did things a little differently with the same result. I removed the 6 10mm nuts holding the lid to the arms, and I left the white ball socket connected and was able to get the 19mm out. I also use a jack handle with a towel wrapped around the end to hold the roof out of the way.

[@TheEddysGarage]

Nice result

[@hawkinsjd11]

I am currently going through this process . I am replacing the gears with a brass pair to hopefully never do this again. I did read your description, bummer I get the metal gears tomorrow. I will try them out and grease the beJesus out of them and see how it goes. I ordered them from amazon so I can return them if required.

[@TheEddysGarage]

Just return them and say they didn’t fit. You are better off having cheap plastic gears brake every 20 years instead of one expensive roof motor

[@valleo1991]

6.30 - Grab the turn lever with a 90 degree pipe wrench, while trying to take the 19mm bolt, which is on a red Loctite.

[@otter25702]

Great video on how too. t I have to do the same on my 986 or go manual.

[@TheEddysGarage]

Glad it helped. It isn’t hard to do and if you convert it to manual the clamshell won’t sit as flush as with the motor

[@Wowwow-wl3kx]

my boxter has hissing sound while driving. recently water pump replaced. it made air coolant leakage. is it related ? how do I fix the issue?

[@TheEddysGarage]

Check my video on the coolant cap and bleed valve. It might be one of those. Did they use an genuine Porsche water pump with the plastic impeller? If not it might be a metal impeller which can make a different sound. Metal impellers can also chew into the block, ruining your engine which is why Porsche uses plastic impellers

[@kendurham2493]

Mine stopped working in the up position and you either have to pop the ball links off or remove the 19mm bolt from the transmission to get the top down so you can fix it, this is accomplished while reaching through the roll bar from inside the car. I couldn't get the links off and I tried using a ratchet and socket but could not keep it on with one hand. I ended up reaching through the roll bar with a 3/8" Milwaukee M12 Stubby impact with the compact battery with a short Milwaukee 19mm socket, once I got the socket on the bolt I pulled the trigger and the bolt came off. I am not sure what I would have done if that didn't work. So if you find yourself with the top up Milwaukee is your friend.

[@TheEddysGarage]

Isn’t it fun 🤣

[@renesanchez5333]

Will this process be the same for a 987 2005?

[@TheEddysGarage]

Yes it is very similar and I used some 987 parts like the plastic covers that had 987 part numbers

[@cmcnichols4]

The plastic is KAPUT! I cannot understand why the engineers at my beloved Porsche decided plastic was okay - I mean...how much $ would that really save? 😞

[@TheEddysGarage]

Better to sacrifice the plastic than to destroy the motor

[@fuvaMaRVBK5pL1uByVjFIfyhTnqay9]

Thank you very much, Eddy!

[@TheEddysGarage]

No problem

[@lefthandown8845]

Great video Eddy, I'm literally doing the passenger side (Aus), what a job!! the 19mm nut didn't come off (just kept spinning) so ended up cutting the plastic drip shield then unbolting the three nuts to get the transmission off, I noticed you had the same problem so how did you eventually get the bolt out, and yes the plastic gear was broken I ordered the parts from Pelican Parts took six weeks to arrive.

[@TheEddysGarage]

To get the boomerang off I had to disassemble the entire transmission and put it in a vice and use a breaker bar. Only then could the bolt to move. I don’t know what lock tight they used but it is like it is welded. The updated 987 drip shields should probably be done anyway. I’m in the Gold Coast, where are you?

[@heldergomes3708]

Having the same issue but I do seem to have a different model of gear... the center bolt has little teeth on it unlike yours is smooth so i'm searching on how to align everything when changing that plastic gear !

[@TheEddysGarage]

It’s easy to align with a drill on the cable unless your arms are bent

[@martingregory5955]

I have a clonk and snatch only when raising the roof and suspect these gears. Its a 2001 986 but don't want to get stranded somewhere. My question is if you get the gears that use the original insert, then how do affix it the new outer? Great info on the vid BTW. Thanks mate.

[@TheEddysGarage]

The old gears will be already In pieces or cracked. My gear that was just cracked only needed a tap with a hammer to get it to shatter and release the centre metal bit that you reuse.

[@anthonyharrington8354]

Try a block of wood to jamb and stop the arm turning

[@TheEddysGarage]

Couldn’t do the wood or risk tearing the rain tray foam. Taking it out and removing the arm later in a vice was the only way. It was easy enough.

[@nicolasgustavofuenzalidair8148]

Hi, I just replaced both plastic gears for Uroparts gears in metal as you did first. why did you decided to replace again the metal ones for a new plastic pair? The metal ones I’ve installed are doing terrible noise, but everything looks okay. With your decision, I’m doubting about the metal gear upgrade. Did you have these noise issues with the metal gear pair? Thanks for the information, very helpful.

[@TheEddysGarage]

The metal gear teeth didn’t line up correctly so I went with plastic. I would rather replace broken plastic gears that bend arms and break the roof motor. Just get the plastic ones.

[@ryank675]

Hi, thanks for the video! I got the same issue, the plastic gear broke on driver side transmission. I found the wire connector is super tight and I cannot unplug it with my fingers. Do you have any suggestion about how to unplug the wire connector? Thank you!

[@TheEddysGarage]

Wiggle and giggle it, maybe a bit of wd40 or similar

[@ryank675]

@@TheEddysGarage Thanks! I will try. Just want to make sure there’s no clip on this connector? So just wiggle and pull

[@ryank675]

Just an update, I used a bent nose pliers to unplug it.

[@TheEddysGarage]

@@ryank675 nice to hear you got it done

[@ahmedalilesh]

Hhh

[@TheEddysGarage]

Yeah bro 😎