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Discussion summary
YOUR RESEARCHsecond gear pop out?
Reported repair
Install g-box detent about 3 years ago and it
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1
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Reported fix
I installed the G-Box detent about 3 years ago and it solved the problem.
Leading evidence: 'Install g-box detent about 3 years ago and it' (1 discussions report resolution; 0 report an unsuccessful attempt). Across 1 matching discussions, The most frequently discussed action is 'Install g-box detent about 3 years ago and it' (1 discussions). For that action, 1 discussions report a resolution and 0 report an unsuccessful attempt. The most frequently reported fix is 'Install g-box detent about 3 years ago and it', supported by resolution reports in 1 discussions. These are forum reports and suggestions, not a confirmed diagnosis.
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Reported fix
I installed the GBox detent and the issue went away for a LONG time.
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Performed · outcome unconfirmed
One thing I noticed was previous owner already installed 997 stock shifter.
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27 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
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Ultimately it didn’t fix the problem and I pulled the gearbox and sent it to Stan at GBox who fixed it better than new.
My personal experience is with the 6 speed in my 2002 Boxster S . It would pop out of second under acceleration but was fine otherwise . This was back in 2015 . Had a local shop pull the transmission and repair it . Has been fine ever since .
In my 99 C4 with 145,000 miles that I bought a year ago surprisingly the transmission seems perfect . No history from the seller if transmission has been apart . I did add the Gbox 2nd gear detent upgrade as a precaution. Knock on wood it will stay healthy .
Has anyone done the Rennkit suggestion of adding the steel ball to increase spring pressure? Just wondering if it has the same results as the Gbox detent upgrade.
https://rennkit.com/wp-content/uploa...t-8mm-Ball.pdf
Before spending any money, try shortening the cable by one or two notches. When I first got mine, 3rd was a bit balky and would sometimes bump out when cold. Then I bought the shift centering tool and reattached the cables based on the center, which included attaching the cable further out(longer). Now the 3-4 line was centered, but the 2nd gear was behaving like the 3rd gear was. So I moved it back 2 steps and its been OK for 4 years.
first time I've seen that mentioned. certainly interesting. i hadn't heard that before but it makes sense. was it bumping out on deceleration or engagement?
Mine happened when cold. It rarely happened when warm. Both 3rd then 2nd didn't feel like they properly engaged, on the edge maybe. Then when taking out the clutch, the transmission would lose the gear. It never popped out in the middle of the gear range. If it didn't pop out during clutch out, it was OK. After the cable length adjustment, it's never happened again. I re-optimized the length again after changing the engine and transmission mounts.
Check your motor mounts as well. My second gear was popping out on track during braking, turns out I had a collapsed motor mount. Changed the mounts and it hasn�t happened since.
Mine was a first gear pop-out issue on acceleration from a stop. First and second use the same detent. I installed the G-Box detent about 3 years ago and it solved the problem.
Mine was both under deceleration & with clutch in when cold.
Neither happened often, maybe every 5 months(5000 miles) or so.
I installed the GBox detent and the issue went away for a LONG time. (~20K miles/2 years)
Then it popped out once while decelerating before the engine rebuild..
During the rebuild the transmission gear oil was serviced and so far, 1500miles+, it has been ok.
It looks like you can use the G-Box detent or a ball bearing under the stock spring. Looks like they are designed to increase spring pressure. Are there any links comparing those?
The posts pretty much cover the gauntlet of things that can cause or contribute to second gear pop-out. My summary:
Wear or damage to 2nd gear engagement teeth (dog ring) and their mates on the 1st/2nd shift sleeve;
Wear or damage to the three-part synchronizer;
Not-quite-right design of the factory shift segment, what CMS calls the
shift arrester
;
Worn engine / transmission mounts;
Shift cable issues.
I've used the CMS part successfully in 996 and 997 Turbo transmissions, do not myself have experience with
GBox's shift detent
, which is a different approach to solving the problem. Good luck!
1st.2nd shift sleeve
2nd gear
Apparently not all pop out is the same. And not all pop out is second gear. First gear and third gear are also listed. Those might be adjustment related .
Is there a difference between pop out under acceleration and pop out under deceleration?
I have read that the detente does not help with deceleration pop out, is that true?
To my experience, no. Either could be caused by any of the issues in my list, to my non-exhaustive experience.
If you're asking about the Rennlist or GBox parts, I don't have experience with either.
So someone posted that the G-Box detente doesn't help with pop out under deceleration. Not sure if that's true or not. Interesting that instead of popping out some Transmissions are more difficult to get out of gear under deceleration. Almost like they get stuck and need to have some throttle applied to release.
I have a 2002 Turbo that I got about 9 months ago. Since then I put about 1,000 miles, well about 600 as first 400 miles were put on the first day driving back after picking up the car. Since then, I experienced maybe 2 or 3 times of second gear popping out. It usually happens when I down shift, particularly when I going downgrade slopes.
I just installed 997 SSK today. One thing I noticed was previous owner already installed 997 stock shifter. I heard that 997 shifters have shorter throw than the stock 996 shifter, and I thought 997 had a long throw. Anyway, I took it out for a short 15-minute test drive after installing the SSK. Within that short amount of time, I experienced three 2nd gear pop outs. All during downshifts into the 2nd gear. At least I took plenty of pictures before installing and marked the cables prior to installation. I haven't gone back to the stock shifter to test yet. I'll probably try it next weekend.
Before going back to the stock, I want to try one more thing. golock911's post intrigued me. I did take bunch of pictures prior to the SSK installation, but I didn't take one after. From what I remember, left side, blue (horizontal movement of the shifter) was in the exact same position as before, but I'm not sure about the right side, black (vertical movement of the shifter). The picture above shows moving left side, blue cable UP. Don't you have to move right side, black cable UP, instead? Won't that make engaging second gear even more?
^^ taken prior to installation (stock 997 shifter)
If this fails, I'll go back to the stock shifter and test again. However, I know that won't solve the problem 100%. Pop out will still happen, but much less frequent. There are a lot of talk about how to remedy this, including CMS Arrester, Gbox detent. All these seem like band aid solutions, I'm okay with that. One thing I heard that that concerned me is that detent puts excessive pressure and could lead into bigger issues. As always, there are many conflicting opinions out there. sigh..
The turbo is a different gear box and the cause of of the 2nd gear pop out has a different solution. Most install an 8mm ball bearing under the detent spring. Do a search for the fix in the turbo forum.
The detent can be used on the turbo. My 996TT had second gear pop out and I tried the detent first, which is cheap and pretty easy to install. Ultimately it didn’t fix the problem and I pulled the gearbox and sent it to Stan at GBox who fixed it better than new.
https://www.gboxweb.com/detent.html
The root cause of this is that the transmission of the 2001 & 2002 Turbos was not assembled correctly at the factory and it has inadequate engagement depth in 2nd gear. The 2003 & up cars don't have this problem.
The fix is to dismantle the transmission, replace the 2nd gear syncro, and reshim the box to 2003 specs.
Once it starts to pop out it only gets worse. If you can avoid lifted throttle decel in 2nd gear you can get by for a long time.
Be sitting down when you read the quote to rebuild the gearbox.
BTW gbox has a less than steller reputation with these G50 gearboxes. Pop on over to the Turbo forum and do a search.
Good info, thanks theprf.
Love to find a bum tranny TT... other than the expensive parts..? building a tight smooth G50 to current specs would be something a nice TT deserves.
As long as we're on the TT subject, whats the best years for a 996TT...?
Dont really know. Its just what i came accross when prepping my gt3 trans. Its the same case but its a little different internally and the gt3 stuff doesnt have the issue so i didnt research any more.
I wonder if it is preventative or protective in the long run. I drove a Fiat Spider in the 70s and it started to pop out. The more it popped out the more it wanted to pop out. It would be nice if it was protective/ preventative.
Well my G50 rebuild was north of 16k so something to avoid. I did change a lot of stuff including better (longer) ratios in 1/2/3 and install more durable syncros and install a pumped gearbox cooler like the GT2/3.
IMO the 2003 6TT is the best year. Transmission assembly was corrected and they still have German made engines (in '04 the engine castings were outsourced to Spain). But really they are all great. There's a really nice 2003 in the classifieds right now.
Oh boy, this is what I was afraid of. As much as I love this car, I feel like I'm going down the rabbit hole. Not to get off the topic, but I still need to weld the coolant line someday as well. All in all, it looks like I may be looking at $30K worth of work. Is it worth it at this price?
Anyway, I appreciate the feedback. I already done some research on the turbo forum and those who had this issue, they all seemed to have difficult time getting it done right. I'll continue the conversation there. Thanks!
