Description

I designed this specialized tool to help replace the linear distance sensor in my 2014 Porsche 981 Boxster S. In my situation, the transmission was left in first gear, which blocked the removal of the distance sensor. To protect the shifting mechanisms, all components on the lower mainshaft must stay axially constrained. Jeff Richardson has published a fantastic video documenting the process to get at this sensor, here is a link to the relevant section of his video at 16m10s:  Rather than using a metal hose clamp or similar tool, I modeled a simple clip to accomplish this job. I am sharing this part as it was helpful for me. I do not know if the dimensions will work on other years or generations of the Boxster or 911 gearbox. This part is to be used at your own risk, I cannot guarantee of performance or be held liable for damage. The STEP file is parametric if you need to change dimensions. My Process I printed this on a 0.6mm nozzle Prusa Mini+ with generic PLA. With solid infil, my print time was 30 minutes on a Mini+ and the part weight was 12g. Supports should not be needed if printed in the orientation pictured below: If you plan to use this as a shop tool, I recommend printing in a tougher material with better oil compatibility, perhaps nylon. The part has an internal feature that engages with the mainshaft's circlip groove. I pushed the tool over the lower mainshaft until it clicked into place. After the tool was seated and secure, I wrapped tape around the clip as a precautionary measure to keep it locked on the shaft.  With the tool in place, I was able to pull the shift fork rearward by hand to release the linear distance sensor. A slice of the tape allows for pulling the part off manually. If you are so inclined, it is possible to further constrain this tool via a bolt and washer that engages on the mainshaft's internal threads. I deemed this unnecessary in my case as I was easily able to pull the shift fork rearwards with finger pressure.