Popping out of second gear

I had this happen a few times since having my RMS replaced, didn't think too much of it. Then it happened three times during an autocross and now I want to diagnose and fix it! When coasting in second gear, usually either downhill or preparing for a turn, my stick will pop out into neutral. I've seen it do it, and it definitely was not in response to touching it or any other control change. It usually happens a couple seconds after beginning to coast. Anyone have a clue for me? Is this something that my mechanic might have left misaligned after the RMS repair? Is it something simple I could attempt to resolve myself (I have very rudimentary skills and tools)? I'm trying to decide if I take it to the dealer hoping it will be covered under warranty, or to the independent who did my RMS hoping it will be their mistake (but getting a better price if it isn't).

if you still have warranty you should take it to the P Dealer to get it fixed.. they might just replace the whole tranny...

I have an extended warranty, not the original or CPO warranty. It might be the same end result, but then again, maybe not...

Could be simple adjustment of cables that control the tranny. Replacement of RMS could have jostled things around just enough to get things out of adjustment. If under warranty, take it to dealer. If not, look online for instructions on Short Shift Kit install. The SSK instructions include disassembly of boot, rear console and pictures of the cable adjustment clips located under your shift boot. You need to move the cable that controls front-back motion forward in the clip about 1/8" for starters, maybe slightly more if that doesn't fix it. Good Luck.

Check this out for more info on this issue. http://www.6speedonline.com/forums/s...ad.php?t=60061

John, This is something I had been wondering about. I was well-aware of the Turbo issues, but a friend of mine had this on his '01 C2 a few years ago. I asked, and was told the pop-out was specifically a Turbo problem (after all, it is a different tranny, if I'm not mistaken). I always wondered, but dismissed it as a fluke. Is it possible it happens to the NA cars, as well? I'm not sure what happened with his car. I know he sold it not too long after he started experiencing it. He was an extremely spirited driver - if anyone could have worn out the synchros, though, it would be him. So is it just a TT problem, or are the NA cars vulnerable as well? Even if in lower numbers.. (and why, if so?)

My apologies. I didn't even pay attention that this was a NA car being discussed. Not sure if it is an issue on the NA cars and I believe too that the transmission is a different part than on the TT.

trannies are way diffrent but if it started happening after a rms i would bet one of the cables isnt locked in place properly

I called my independent mechanic, the lead mechanic where my RMS was repaired, and he said he doubted it was related, but he'd check it out for free. He did indicate that the 996 had a history of problems like this, and that the solution was usually a new tranny. Any other non-turbo 996 owners had this problem? If so, this will be a good first test of my extended warranty. It could pay for itself completely on the very first incident, in the very first month... :/ I'll let y'all know what they find!

With whom do you have your extended warranty? I have mine with Western General and they were quick and liberal. I just got the car back for a new RMS, ISS, water pump and idler pulley. All that for $50 out of my pocket plus $12 for crank bolts that they didn't cover. I'm sure if it's a valid warranty issue, there should not be an issue with the claim. Good luck, however.

My tranny is being replaced as I type this.... well actually it is being removed so that a whole new one can be installed when it gets here.... Popping out of 6th and grinding into 2nd and 3rd, those were my symptoms. I don't know how it happened, the car was driving just fine when I parked it in front of the grocery store......... My extended warranty is with GE and they are paying for all of it, less the $100 deductible, including the tow from Bakersfield..... even with the roll bar and racing seats in the car I'd have it looked at as soon as possible , especially if you've got a warranty.

delaers can now get parts and have the tools to rebuild na transmissions, and i have a set of 2nd gear sycros and a 2nd gear slider that i got from a customer whos tranny was unsaveable

Irk, The same indy who did the RMS tells you that you may need a new tranny? If they still say that after looking at it, I'd get a second opinion before you put your 3rd party warranty to the test. If everything was fine before the RMS, it's pretty hard to believe coincidence. Not trying to be disrespectful, just my $.02.

I have an independent mechanic who says he sees this problem A LOT, even with N.A. engines, and that the solution is a new tranny. I've always been a bit skeptical, however, as I don't see the problem discussed that frequently on any of the forums. Good luck.

Sychros have gone bad........had a Corvette with the same issue, its not a "porsche" issue. Can rebuild or replace.

hey Arnee... i am actually checking out the website for western general and it doesn't look like they warr. cars in california... how did you get yours from them....?

Well, I said I'd report back... Mechanic could not reproduce the gearshift popping out. However, he claims this is a weakness of the 996 transmission, that they use a ball bearing based something-or-other, which is a weaker approach than whatever else they could have used. Can you tell how technical I am? I can't even remember the exact part names, but it made sense as he described it... Anyway, he says it will degrade until it fails to stay in gear at all. No prediction on how long that will take. Since I have the warranty, he recommends using it until it fails reliably enough to reproduce easily, then go get it replaced. Sounds like a plan, so I have ~4 years to make it fail. He expects it to fail sooner than that, maybe even real soon. He knows my plan is to take it to the Porsche dealer for the repair, so he has no motivation to exaggerate. So, it's wait and see on the tranny, I guess. Interestingly enough, I headed out to a PCA social last night, and my left turn signal was blinking rapidly. I assumed it was a bulb, and verified that the front turn signal was not working. Since I was taking the car in anyway, I asked them to replace the bulb to save me the energy of finding the bulb and doing it myself. Well, it wasn't so simple. The bulb was fine, they switched it to the other side and it worked fine. They swapped the socket, and it worked fine in the other side (and the right one did not). So, they checked the connection from the wiring to the litronics assembly was working (delivery power to the correct connections). Diagnosis? Short inside the litronics headlamp assembly. I'm taking that to the Porsche dealer tomorrow, but I expect to see them replace the whole thing. Something like $2000 for that part, as I understand it, so my warranty is going to pay for itself easily. Now if I could just get the warranty to pay for the tires I'm going to need after running the autocross this weekend...

So, it's common to ALL 996's, this transmission "issue" ?1?!!?!?!?! I thought the "only" thiings that 996 owners should watch out for that is common are the RMS/ISS.

Not sure if it's best to describe the failure as 'common', but according to this particular mechanic, it's a weak design from which he has seen numerous failures. As far as common failures, I would add to your list the coolant tank cracking, at least as far as I understand it.

Final update on this, the turn signal problem, according to the dealer, was 'loose pins in the wiring harness connector'. They adjusted the connector, charged me $82 for my trouble, and now I can signal my left turn intentions. I'm doing autocross again this weekend, we'll see if it shakes loose again. If so, it's covered for free under the dealer's 2 year warranty on their own work. Dealer upsold me on an alignment, after scaring me with bad tire wear. Claims it was way off, and damned if it doesn't drive even better now. I guess I should have had this thing aligned as soon as I bought it.

I'd strongly suggest a change of transaxle fluid for the shifting issues. My C2 was popping out of 2d gear consistently, esp. when cold. I changed the fluid to BG with a friction modifier they sell. Cured the problem for two years now. The whole concept of a lifetime tranny fluid goes right along with the idea that Porsche sells you a new tranny instead of stocking and selling repair parts. Although they have started recently. Probably trying to clean out their warehouses.

My warranty was with western general too.

Aren't you forgetting the cost of the warranty?

Warranty cost me $3,000. Total bill was $2,2xx. ALMOST paid for itself.

Could be the cables just need to be asjusted or could be the common syncro problem. One is cheap one is $$$$$. Good news is that PCNA is now selling parts for the tranny so you are not stuck with buying a whole new tranny if it is out of warranty. Also check out PowerHaus II, they have an upgraded syncro kit.

Hummmm, tranny parts made available relatively recently. I wonder if engine parts will become available when the in '08 when the standard 4/50,000 warranty run out on the '04 996 cars?

It's a common problem on the 6-spd tranny used in C2 and Boxster 'S'. My buddy had the same problem w/ only 30k on his 04' Boxster 'S'. He took it to Niello Porsche,had a mechanic jump in the car with him,got it to pop out of 2nd for no reason at all while driving and two weeks later he had a new tranny.

parts are availabe, its not a matter of that, its the complet cost of taking one apart and fixing it, its way cheaper and more cost effective to replace it....... unitll a m96 engine hits 16k+ its going to stay that way