When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
I was wondering if someone could explain the 2nd gear pop out that ultimately leads to damaging 2nd gear. I am working on an 02 996 and I have the gearbox out and the nose cone off. 2nd gear is pretty wasted and I would like to replace the necessary parts to fix 2nd gear and keep it from popping out so it doesn’t get destroyed again. Any help is greatly appreciated.
Gear popping out of gear is normally a sign of excessive wear on the syncro ring, and syncro hub. How many miles and what kind of use did this gearbox get? Do you have any pictures of the synchro ring and the dog teeth?
I was wondering if someone could explain the 2nd gear pop out that ultimately leads to damaging 2nd gear. I am working on an 02 996 and I have the gearbox out and the nose cone off. 2nd gear is pretty wasted and I would like to replace the necessary parts to fix 2nd gear and keep it from popping out so it doesn’t get destroyed again. Any help is greatly appreciated.
Duke , how hard is it to get the nose cone off, I'd like to inspect mine whilst it's out the car, how do you get the shift lever off??
Duke , how hard is it to get the nose cone off, I'd like to inspect mine whilst it's out the car, how do you get the shift lever off??
Look it up on YouTube. There is a really good multi episode video showing how to take it all apart but besides that, just do a search here, there are at least 2 threads on this with detailed pictures. I've added some when I took mine apart.
....What’s the most cost effective long lasting repair? Thanks.
Besides that synchro ring and maybe some other small parts in that selector ring, you will need to replace that gear with a new one. Check YouTube for the video and the couple of threads here for the procedure. what shape is the pinon gear bearing in?
If you zoom in on the picture you will see the top teeth that engage 2nd gear are all worn off. How hard it is to get the gears off to replace the damaged parts? Will I be able to use standard pullers or do they take special pullers? Thanks.
@DukeTJ8 agree, teeth are trashed, odds are the brass syncros and steel cones (the grippy surface on the face) need to be replaced too.
Gears come off with a regular 3 arm puller, but you need a big one!!
@Porschetech3 has talked about an issue with shimming of the gear stack that Porsche struggled with that led to 2nd gear popout issues, at least in early transmissions.
There are at least three bandaid solutions available to mask a second gear pop-out, but I understand that the proper fix is to properly re-shim the gear stack. Not a project for the faint of heart!
For someone who has never taken a transmission apart....what am I supposed to see in this picture that tells me the 2nd gear is trashed?
You see the small teeth just above the big one? the top of them is chewed up. They sort of supposed to look the the small teeth above those ones. The big teeth are the actual 2nd gear but the little ones above it, that are chewed up, are what works with the sychro ring when the 2nd gear needs to match the speed during gear change.
If I just replace the damaged gears and synchros will I still have the 2nd gear pop out problem? How long will it last before it starts to happen again?
You see the small teeth just above the big one? the top of them is chewed up. They sort of supposed to look the the small teeth above those ones. The big teeth are the actual 2nd gear but the little ones above it, that are chewed up, are what works with the sychro ring when the 2nd gear needs to match the speed during gear change.
Thanks....that was real helpful...now that I see it, seems obvious ...this is what I love about the forum....learn so much from you guys.
If I just replace the damaged gears and synchros will I still have the 2nd gear pop out problem? How long will it last before it starts to happen again?
IMHO, you will most likely still have the pop-out, but it's hard to say without being there.
The worn teeth can impact engagement since the points are to ease engagement. I don't know if (or to what extent) the cause pop out, since once the sleeve is engaged, there is a positive lock up between the shaft and gears (at least as I recall from fixing my 2nd gear grinding issue).
Like I said above, there are at least three bandaids. They are the G-Box detent, the CMS shift arrestor, or a ball bearing "spacer" in the stock detent. But they are all are workarounds that mask the real issue.
People much smarter than me tell me that pop out can be caused by the gear stack being shimmed wrong (...so I read, no personal expertise).
04-07-2020, 12:58 AM
996 2nd gear pop out Gear and Synchro damage.
...this is what I love about the forum....learn so much from you guys.