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YOUR RESEARCH2nd Gear Grinding and Pop-Out when cold
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Fill the 996 gear box is very sensitive
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Also make sure your gear box is not over filled, the 996 gear box is very sensitive to over filling.
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I run Redline gear oil with the suffix NS (I think that's it) that stands for No Slip.
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Suggestion · Original poster
Sounds like a fluid flush and re-fill will help, and that is part of the 90,000 mile service.
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Suggestion
You can try to run a gear oil with no friction modifiers in it to help the worn syncros not slip as much.
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Anyone have any information about cold shifting into second gear? My '02 996 sometimes grinds as if I haven't depressed the clutch when it is cold. Problem goes away after the tranny warms up. Had the car for about a year now and it has always done this. I avoid the issue by shifting from 1st to 3rd until it warms up. Kind of annoying...
2002 996; Arctic Silver/Black leather. Turbo-twist wheels, K&N cold air induction
I have the grinding issue when cold, but not the pop-out issue. I assume that my synchros are going bad for 2nd gear, and I'm planning a transmission rebuild in the near future.
Your second gear syncros are way worn and the trans needs a rebuild. Mines the same way, though not so warn that it's popping out of gear yet. I just don't downshift to second when it's cold, and even then have to gently push it into gear (upshifting is always fine, cold or not). Still, I'm gonna have a rebuild done at some point.
It won't get better on its own. Anything you do outside of a rebuild is just a band aid. Still, sometimes band aids can last awhile.
Great... Any idea how much that rebuild is going to cost? I just put new tires on the car ($1,000), and I need to do the 90,000 mile service in the next few weeks (another $1,000). Other than cold shifting, the car runs PERFECT.
$1,000 for a 90K service, WOW! You must be taking it to a stealer. If you do everything on the list that is still a lot of money, and half of the stuff on the list is just a dealer looking for more items they can charge you for.
Just shift from 1st directly to 3rd when cold since you said it works fine after it is warmed up, the price for the rebuild is not cheap. Another alternative is to swap different brand and mixes of transmission fluid. Also make sure your gear box is not over filled, the 996 gear box is very sensitive to over filling. Not like the older G50 box where you just fill it all the way to the filler hole until fluids back flows. I believe it only takes 2.7 liter to fill, if you over fill it it will not shift properly (as I have done this on my own car)
Sounds like a fluid flush and re-fill will help, and that is part of the 90,000 mile service. I will see if that helps the problem. If it dosen't, then I will look in to more drastic measures. Thanks for all the notes, guys!
My 2nd gear doesn't pop out, but does grind when downshifting when cold (never when upshifting, cold or hot). This is cause from worn syncros not syncing the gears before they mesh. Excessive grinding of the gears, combined with some other factors, ends up causing the gears to pop out when under heavy load. Syncros can get worn from very aggressive downshifting with high road speeds and lower (non-matching) engine/gearing, so the syncros end up taking the brunt of bringing the trans up to speed with the road speed.
You can try to run a gear oil with no friction modifiers in it to help the worn syncros not slip as much. I run Redline gear oil with the suffix NS (I think that's it) that stands for No Slip. It won't fix it, but it can help.
I've just learned to drive more carefully when cold and don't downshift into second at stops until fully hot.
Occasionally this issue pops up but it's not as common as I was led to believe many years ago when I bought my first 996.
My 2002 has 103,000 miles on the clock. I drive it hard and so far I have no issues with grinding or popping.
I rev match all my downshifts and go easy slow into second, even more so before it's warmed up all the way.
Also, a year or so ago I had the trans fluid swapped out for a blend of Redline oils designed to limit synchromesh slippage. The gear change is a bit more balky, but I believe it preserves the dogs (which causes the grinding)..
redridge
+100
I would defiantly try this:
http://www.gboxweb.com/detent.html
for ~45minutes of work (1/2hr of it is jacking the car) You may be able to minimize/stop the popping out of gear.
