this was mainly a flaw in the early 00 01 02TT correct?I'm looking at an 05 Turbo S and certainly don't want this to be an issue!!

 

Can happen to any 996 really,

 

Yup, I drove a 2003 non-X50 that had it.

If you can, I'd use it as a negotiating point on the sale price.

My mechanic has done these transmissions before- and as long as your mainshaft is still good- it won't be too expensive.

 

Here's what a 2nd gear pop-out looks like !

http://www.youtube.com/watch?v=w_I7rjKzIjE

In my car, the problem happens frequently when the transmission is still cold but gets better and never happens when transmission/oil gearbox is hot.

 

If a car had this issue does it usually show up pretty early in it's age or can it show up later like around 40k or 50k miles as well?

What percentage of TT's seem to have this issue?

 

This seems to be a great pointer to where the problem might lie...

http://www.gboxweb.com/996shimtip.html

 

When I picked up my car last week, I got a lesson from my indy on what the whole 2nd gear pop out is all about...

There are two bearings that contribute to this issue. The real culprit starts at PORSCHE AG, where the transmissions were assembled. If those bearings weren't properly shimmed on install (Which requires proper alignment and clearance on the main shaft and ailigned with the shift forks properly, then the bearing will wear pematurely. My gearbox did not have this issue at all, and was pretty well used heavily at the track. However, a number of members have suffered this issue.

The bearings are not hard to replace, but while you're at it, you'll end up doing syncros or other "stuff" and have a minimum of $2K in it... While you're in there, I'd absolutely swap to the GT2 Clutch Hydraulic system and get the pentosin actuated garbage out of that driveline.

Mike

 

First gear is a machined piece within the 996TT mainshaft. I can post a pic if you'd like to see it... There's no machining that piece off, as it must be machined... Which is why most of us upgrade to the newer shafts available, which in turn costs a bunch...

Remember, there are two parts to 1st gear... There's a "first on a rod, and a first on the mainshaft..."

My 996TT mainshaft is upstairs in my home office... I look at it often!

Mike

 

I've recently been told by someone very knowledgeable that the GT2s never had steel synchros. Can anyone confirm this?

 

In the PET both G96/50 & G96/88 have the same part#'s for synchros.

 

Not only was I told that, I saw a GT2 box open on the bench at the shop, and it had brass syncros that were being upgraded.

I don't think any of the 996TT or GT2/3 based cars came with steel syncros. Mine now has a mix... steel in 3/4 and brass in the others... 1/2 are exceptionally expensive to go steel on.

Mike

 

Mike, who did your transmission upgrade for you? I don't know if you can say this openly or not, if you can't, feel free to PM me.

Thanks!

 

Strange. Lots of conflicting information on this subject.

I just sent an email to Gbox Performance Transaxle (Porsche transmision experts http://www.gboxweb.com/ ) asking them to clarify if GT2's have steel synchros, while 996TTs have brass. Here is their copy/pasted reply.

He also told me that the Turbo S and X50 did not have steel synchros. Only the GT2.

 

Yes, very confusing indeed. My indy has domn a few and had for a fact seen steel synchros and in fact told me that the "fix" for mine was the GT2 steel synchros. I wonder if it is up to the factory to install whatever they have "laying around" and they are in fact not consistant?

 

Mike, didn't know you had the pop out issue... and did you fix it already?