2nd gear popping out......

[sean m]

All,
Just drove my 77 911S this afternoon. 2nd gear is now popping out of gear and won't stay in.
All other gears are fine and work properly. I know absolutely nothing about the transmission and won't be working on this myself.

Questions.....
1. Is this simply the syncro or possible additional problem? Best guess
2. Obviously, I need to get some work done....what else "while we're in there" should be done?
3. Estimated cost if it's just the syncro for 2nd.
4. Best Atlanta shop to do the work?


I know this is a little vague......but this group has never lead me astray.

Thanks for any advise.

[john walker's workshop]

Other than not getting all the way into gear due to worn shifter bushings, it's usually that the dog teeth that hold the syncro ring captive have broken off, allowing the ring to expand, which blocks the shift sleeve. Little teeth are usually found in the drainplug magnet in this case.

[sean m]

Thanks John......I assume this means a complete transmission rebuild?

[john walker's workshop]

If you have o go in, no sense doing it half way.

[nomore]

Make sure all the shifter bushings are good before you rebuild the transmission. When I first got my '74, I had no 2nd gear at all. All new bushings and tinkering with the spline adjustment and
all is well. If the problem just appeared, start with bushings.

[jlex]

And change the fluid first to see if you can detect any metal in the fluid. May be just a bushing or coupler problem.

[Reiver]

Originally Posted by jlex

And change the fluid first to see if you can detect any metal in the fluid. May be just a bushing or coupler problem.

If your adjusting depth (for/ aft at the coupler) has changed that can also lead to a barely seated gear change.

[94teener]

FWIW - I had the same issue with my 914 side-shift after a very long resto process. I thought it might be the linkage and spent lots ot time trying to adjust the throw. My mechanic drove it and said it was a trans problem. I looked on craigslist and found several - one for $200 (!) - the seller said was not sure if it worked as it had been stored for years and offered me money back if not. I took it home swapped over a few of the new bits I had put on the old one - installed it and it worked great. Not sure if you can find a good used one but you may want to compare pricing between a repair and trying to find a good used one.

[sean m]

Thanks all........I'm taking to Eurofed in Johns Creek GA to get their thoughts.

I'll let you know

[yelcab1]

Over 10 years ago, I bought a used working 915 gearbox for $500. I am very sure those are no longer the going prices.

[kevingross]

Originally Posted by yelcab1

Over 10 years ago, I bought a used working 915 gearbox for $500. I am very sure those are no longer the going prices.

You can probably find one for $500. But you'll drop $5 - 10K to make it right.

[Nick Triesch]

But can you really make it right ? I have read posts on the forums that say even after a rebuild the 915 does not shift perfect. I figured out mine years ago.

[AirJose]

Hi Sean,

If all fails these folks are not far from us. No personal experience with them.

https://www.cogscogs.com/About-Us_ep_7.html

Jose

[Matt Monson]

Originally Posted by Nick Triesch

But can you really make it right ? I have read posts on the forums that say even after a rebuild the 915 does not shift perfect. I figured out mine years ago.

Well if someone posted it on a forum, it has to be true.

[Walt Fricke]

A shift linkage (external) alignment issue typically affects two gears, in this case if you can't get it to stay in 2d because the connector is "too short," you ought to have an issue with 4th also. Doesn't cost much but some time to see if adjustment will help, but I'd not count on it.

Chances are you will need to replace the 2d gear "teeth" (not the gear's teeth, but the part which is pressed into the side of the gear, has lots of small sharp teeth, and when in gear engages the corresponding teeth on the operating sleeve, which moves back and forth between 2d, neutral, and 1st. And which you can't buy from Porsche, so you have to use the aftermarket). And the operating sleeve, because if the teeth on the gear are worn a lot, then the OS is worn as well. And the synchro ring itself.

You can look up the prices for these parts easily enough, and the cost of a gasket set (though a guy can do without that). The tricky parts are a) the cost of qualified labor, and b) what various other parts in there are going to look so worn that replacing them too will have to be discussed.

[sean m]

All,
Thanks for your input. Took the car to EuroFed in Duluth GA. Shift bushings were shot. Replaced them as well as put in the Wevo shifter.

What a difference......didn't realize how "sloppy" the shifting had become.

The guys at Eurofed were great.

[jlex]

Well, looks like you dodged a bullet there... Christmas came early for you.

[NYNick]

Cheap fix. Think I'll do the same on my sloppy 72.
Feels like my old 73 Super Beetle.