915 2nd gear woes

[Brickwhite]

My 915 (86 Carrera) is not engaging 2nd gear, probably synchro.

Are these tough to find parts for or tear apart? I've rebuilt 4 speed GM Muncies and Austin Healy transmissions before.

I'm newer to 911s, not cars

Could it be the clutch cable?

Are there good guides or books you would recommend?

What brand of syncrhros should I stay away from what other while I'm in there should I do?

I know I won't know much till I get her cracked open.

[sean m]

Hey Brick.......I've got a 77S with 915 trans. 2nd gear would pop out of gear and wouldn't stay in without holding it in place.

Replaced the synchro and problem solved.

Not sure if this helps your issue as I'm not a transmission guy.

[john walker's workshop]

Sometimes the dog teeth on the gear break off , the syncro ring expands and blocks the shift sleeve from engaging the gear. Drive it much more and the brake bands and stop dogs can come loose and go through the gears like a blender. Drain the oil and see if there are little teeth in the pan.

[Brickwhite]

will do... she'll be put back in the garage till I can get to it.

[Matt Monson]

Pete Zimmerman has a very thorough and complete wiki of everything you might want to know. Our host here sells all the parts you need.

If you buy teeth get the Rausch and Spiegle version.

BRB, there’s a fs ad with the key tools you need. Let me find it…

[Matt Monson]

Sorry. He sold them.

[shoooo32]

I learned most of what I know about 915s from Pete's wiki, fellow Pelicans, and the bentley manual How-To: Porsche 915 Transmission Repair Tutorial Part 1 - Porsche Wiki

A few years back I 1-2 hot shifted my SC and busted the stop, wedging pieces of it under the clip. The synchro wouldn't engage so I had no 2nd gear. Easy fix - replaced the broken parts and all set.

[kevingross]

I'll also recommend Pete Z's tutorial. If you're replacing the 2nd gear synchro, you will also want to replace the 1st/2nd shift sleeve. You should measure the installed diameter of the new synchro when installed, and if the measurement is out of spec, replace the engagement teeth (dog ring) on the gear. If the engagement teeth are hammered, that's another good reason to replace them. Good luck with the project,

[evan9eleven]

++ for Pete's tutorial, between it and this forum I got through a comprehensive rebuild of my 915 box, which works really well now.

[Brickwhite]

Driving back to the Garage (store my 911 in an off site garage), I could no longer get the 915 into 4 gear either.

Maybe Clutch Cable...???

I got it back in my garage with 3 gears, I'll get it up in the air and examine how long the pull is.

[Matt Monson]

Start with the shift plate on the bottom. It might have a broken tube on the selector fork that guides the main shift rod.

Drain it first.

[Brickwhite]

I checked a couple things,

The pedal, the cable, shifter and the selector fork.

The pedal seems to have some play..