Thanks.

 

Holding my trust in RAC Performance in the Dallas area. They have indicated they will stand behind the work done in their shop. They should be authorizing me to have my nearest Porsche dealer (Penske Scottsdale) pull the tranny and assess what's needed to fix the pop out issue. Can't ask for more than that. Just waiting for the final approval. Stay tuned...

 

check it against this list http://californiamotorsports.net/pro...ear-repair-kit

and add this

http://californiamotorsports.net/col...shift-arrester

 

Thread back from the dead, due to being a lurker I can’t send PMs so forgive me. If Terminator is still active on here could he share the details for who he used?

Also for anybody else that can help, condensed version...

Box rebuilt with new 2nd and shift sleeve, all bearings new, still popped out of 2nd, I lost patience (the story Is way longer than this..) and used the car for a while just holding 2nd every time, my car has around 600-650hp and stripped a couple of teeth off 3rd gear. Got lucky and NO other damage so rebuilt again with 997 GT2 1-3, CMS arrester and CMS billet centre plate as I was concerned wear to the centre was contributing to bad tolerances and 2nd gear popping out. Every other component described as perfect and unworn so reused. Box has been back in the car for 670 miles, been running at 0.9 bar and making sure everything’s ok as a lot has changed on the car and it’s been a while since it’s been used, been awesome to have no 2nd gear pop outs! Went back to 1.4 bar last night and decelerating at around 5500rpm in 2nd it popped out of 2nd, I’ve literally been up half the night stressing about it. Additionally, 1st and 2nd sound a bit marbles-in-a-can-like on decel or light load when the gearbox is warm, like I’ve got a LTFW but I haven’t, I’ve been hyper paranoid about any noises so been paying close attention even though it’s at a noise level I don’t think most people would notice, but enough to get my attention. Gearbox has been built by an extremely experienced builder, I’m not looking for reasons to blame the builder, just any information I can go back to them with.

The new needle rollers done when it had the full rebuild were original plastic ones, and the syncros original not steel. Quite honestly at the time I’d spent thousands on 2 other builders totally messing me around, and I was happy to agree with the logic that the stock parts had been fine for 70k miles before so why stress it second time around. I’m now concerned that perhaps the plastic needle rollers aren’t happy with the torque level or something, as it appears the problem has only reared it’s head once I returned boost to normal.

 

i stole this from another thread so i'll post the thread too https://www.6speedonline.com/forums/...r-specs-2.html - bottom line, you need a rebuild. replace whats worn, fix the shim stack.


"while that all might well be so, i'm not sure that is the "cause" of the original issue itself. that had more to do with improper tolerances of the shims used, not the gears themselves.

the dogring of the 2nd gears triple cone designed synchromesh gets 'rounded" owing to a missed shift and once "rounded' will never engage as its was designed to. in addition, porsche discovered that their gear stack placement ( and where 4th gear sat in the stack (iirc?) was not within the proper spec so as to allow the 2nd gear to fully engage, further exacerbated by a rounded dogring, per above.

whether any of this has been addressed in your detailed post isn't clear to me nor does it make any difference. if you don't address the fact that porsche's original tolerances were not optimal, for the engagement of the gear with a perfectly fine synchro and accompanying dogring, then the significance of a slightly rounded dogring takes on an added significance and also creates a propensity for improper gear engagement, that does not exist once the gear stack placement is changed with PROPER shim placement so that 4th gear is placed a bit differently in the gear stack placement. yes, it's millimeters at most.

but, that's why once porsche changed the shim tolerances and placement, the problem occurred less and less, ( or not at all ) until it was no no longer a prevalent issue.

conversely, rebuilt gearboxes ( even from porsche themselves ) that were initially replaced with new 1/2 mainshaft gears and all new synchs tended to exhibit the same symptoms as the original CAUSE of the defect had not initially been addressed!

once the shim tolerances were changed by porsche to alter the gear stack placement, the issue of 2nd gear pop out miraculously stopped happening.

whether you have or not addressed that in your play by play w pics, is beyond me. the issue, and the proper fix for the issue itself are not. but that's why a detent, an 8mm ball bearing, or a shift arrester work, as they mechanically limit the movement in the box. when the properly shimmed gearbox would also eliminate predisposition and/or the cause or propensity for a rounded synchro dogring to improperly engage 2nd gear, resulting in it "popping" out of second gear.

whatever works!..i had mine rebuilt properly ( twice ) after much back and forth with both porsche and pcna. good luck."

 

wierd to see stuff i wrote 5 years ago. i couldn't do it again lol

 

I picked up a 2002 996 TT almost 2 months ago, the car came with a Markski 850hp turbo kit and I discovered occasionally a 2nd gear pop out during low speed when I let go on the gas paddle. I have recently installed a GBox Shifter Detent along with 997 Short Shifter Console, I took the car out for a drive over the weekend, the car droves fine on the twisty but on my way home the 2nd gear popped out at low speed when i was making a turn.

I am looking for an advise if by upgrading it to CMS Shift Arrester would it help on the 2nd gear or I might as well have the transmission rebuild?

Thanks in advance.

 

given the relatively high cost of opening the gearbox and replacing the necessary parts.

the smartest thing to do would be to try either the cms arrester or the "ball bearing" insert which has also saved more than a few who caught the issue "early enough". that's the key. catch it before the dogring - synchos become too worn and "rounded".
so, i would try it yes, if were you.

also do a search here and r-list for the "ball bearing fix" i believe that tim941nyc? a longtime tech/contributor here has a comprehensive thread here on it .

if my memory serves.

here's some info i posted years ago that jdexter posted above. it's fairly accurate informationally speaking.


"while that all might well be so, i'm not sure that is the "cause" of the original issue itself. that had more to do with improper tolerances of the shims used, not the gears themselves.

the dogring of the 2nd gears triple cone designed synchromesh gets 'rounded" owing to a missed shift and once "rounded' will never engage as its was designed to. in addition, porsche discovered that their gear stack placement ( and where 4th gear sat in the stack (iirc?) was not within the proper spec so as to allow the 2nd gear to fully engage, further exacerbated by a rounded dogring, per above.

whether any of this has been addressed in your detailed post isn't clear to me nor does it make any difference. if you don't address the fact that porsche's original tolerances were not optimal, for the engagement of the gear with a perfectly fine synchro and accompanying dogring, then the significance of a slightly rounded dogring takes on an added significance and also creates a propensity for improper gear engagement, that does not exist once the gear stack placement is changed with PROPER shim placement so that 4th gear is placed a bit differently in the gear stack placement. yes, it's millimeters at most.

but, that's why once porsche changed the shim tolerances and placement, the problem occurred less and less, ( or not at all ) until it was no no longer a prevalent issue.

conversely, rebuilt gearboxes ( even from porsche themselves ) that were initially replaced with new 1/2 mainshaft gears and all new synchs tended to exhibit the same symptoms as the original CAUSE of the defect had not initially been addressed!

once the shim tolerances were changed by porsche to alter the gear stack placement, the issue of 2nd gear pop out miraculously stopped happening.

whether you have or not addressed that in your play by play w pics, is beyond me. the issue, and the proper fix for the issue itself are not. but that's why a detent, an 8mm ball bearing, or a shift arrester work, as they mechanically limit the movement in the box. when the properly shimmed gearbox would also eliminate predisposition and/or the cause or propensity for a rounded synchro dogring to improperly engage 2nd gear, resulting in it "popping" out of second gear.

whatever works!..i had mine rebuilt properly ( twice ) after much back and forth with both porsche and pcna. good luck."

 

Thank you 02996ttx50 for the write up. I have only put <300 miles on the car so far and I replaced the shifter detent hoping it could fixed the issue but didn't seem like it. I am going to talk to the dealer where I purchased the car from as I basically trusted their inspection report but the car seem to have many issues, discovered a broken sway bar drop link, expired rear tires, now rear spoiler hydraulic fluid leak and 2nd gear issue see if able to get some compensations or even to a buyback.

Let me look into the 8mm ball bearing insert too.

Thanks!

 

you're welcome. hope it helps informationally at least as you'll be able to tell them what they don't "disclose".

i bought a 996 turbo from a porsche dealership with CPO warranty coverage and had to battle them for the repair as their CPO checklist obviously didnt disclose any 2nd gear popout. in fact, a lot of cursory PPI's wouldn;'t necessarily find it either, since it mostly happens under load downhill in 2nd.

until it gets really bad.

the gbox detent has ( near as i recall ) the least amount of success. the cms arrester is better but this ball bearing is supposed to have a high degree of success. really, seacrh for that guys thread on it here. it's extensive.

also, arm yourself with as much indisputable info on this malady as you can, and get back to the seller for some redress... and - GOOD LUCK.

 

I have ordered the ball bearing and waiting to bring the car in to have the ball bearing install on the gbox detent, the earliest appointment I can get is 09/14. We'll see how it works out.

 

I'm fortunate to have never had the pop out even one time. I've owned my car about 10 years and knew of the problem before I bought my car. I'm reluctant to let anyone drive my car for that reason, even with me riding along. I think all it takes is making the shift from 1st to 2nd to quick and doing that too often. I always let the r's drop a bit and let the shifter ease into 2nd when it's ready. You can feel this in the lever. I've rebuilt trans' for years and can visualize what's happening mechanically when making shifts. I want my trans to last issue free and that's more important than seeing how quick I can force a shift.

 

same here. i hate to let even a tech drive it.
all it takes is one misshift.

 

Here is an update from my 2002 996, I added this 8mm ball bearing insert inside gbox shifter detent and so far so good.

 

I habe about 80k miles on my 2001 996 and it's popped maybe 15 times.
Just ordered the detent pin from GBOX.
Just moved to Florida on the Treasure Coast around Jupiter. Can anybody reccomend a good shop to work on my car?