Hard to Shift Into 2nd

Rot 911 · 11-19-2001, 08:09 AM

Mikkel, in his winter posting, said: "On a side note my gearchange has gotten much better in the cold weather after I recently had the stock gearoil replaced with synthetic gearoil. However as much as third gear has become a joy to select, second gear has become harder to select? Sometimes it's fine while other times I need to actually use force to pull the gear lever into second? It wasn't like that before the oil change. If third gear has improved so much why has second partly gotten worse with the change to synthetic oil?"

I have the same problem on my '86. At times will shift into 2nd with no problem. Most times I really have to pull hard to get it into 2nd. No grinding, just a lot of resistance. Any suggestions for both Mikkel and me? By the way I'm running Swepco and this problem has been during warm weather, who knows if it will get worse in cold weather.

tmctguer · tmctguer's Garage

it may be time for a linkage adjustment, assuming no other faults exist in the transmission. i had a problem shifting from 2nd to 3rd and new shifter coupler bushings and a linkage adjustment appears to have cured that.

TimB · 11-19-2001, 01:37 PM

I have a lot of resistance into 2nd. It feels like I hit a stopping point then have to pull hard again to engage the gear. First gear isn't as bad but similar.

Any recomendations for GOOD 915 mechanics in the Bay Area? I am in the East Bay.

Tim

ffilips · 11-19-2001, 02:19 PM

I have an 86 951 that does this as well. No problem down shifting from 3rd to 2nd, but on the up shift from 1st to 2nd it's like it hits resistance and has to be pushed into gear.

Early_S_Man · 02:55 PM

I would recommend going to a good GL-5 SAE 85W-140 gear oil, changed a couple of times over the next 1000 miles or so, then put Swepco 210 in it ... slicker, thinner gear oil is NOT a good idea with a balky 2nd gear synchronizer in a 915 transaxle!

john walker's workshop · 11-19-2001, 03:06 PM

lately, i've been using kendall limited slip additive in my rebuilds and in trannys that are hard shifting, (not grinding, but firm or difficult), along with the usual kendall 80/90 GL5 gear oil. it may be my imagination, but it seems to improve shifting. you don't need a limited slip to use it.

BlueSkyJaunte · 11-20-2001, 06:44 AM

Quote:

Originally posted by Early_S_Man
I would recommend going to a good GL-5 SAE 85W-140 gear oil, changed a couple of times over the next 1000 miles or so, then put Swepco 210 in it ... slicker, thinner gear oil is NOT a good idea with a balky 2nd gear synchronizer in a 915 transaxle!

Warren, are you recommending a switch to 210 (is there such a thing?) or is that a typo? Thanks!

martinh · 11-20-2001, 08:53 AM

I had just this problem on 2nd, so I opened it up to see what was happening. What I found was that the rough coating on the synchro ring was worn through and was showing shiny metal. It's my theory that with the loss of friction the slider and dog teeth were taking too long ( or needing force on the lever) to synchronise. I always found that it would go in if I gave it time, but trying to do a quick shift needed force.

I can't say if I cured it yet as I'm not back on the road, but I have a good feeling.

By the way, changing 1st and 2nd synchros is no big thing on the 915, and doesn't need any special tools other than a couple of big sockets, and you don't need to loosen the shift forks like the books say.

rob911 · rob911's Garage

Quote:

Originally posted by martinh
I had just this problem on 2nd, so I opened it up to see what was happening. What I found was that the rough coating on the synchro ring was worn through and was showing shiny metal. It's my theory that with the loss of friction the slider and dog teeth were taking too long ( or needing force on the lever) to synchronise. I always found that it would go in if I gave it time, but trying to do a quick shift needed force.

I can't say if I cured it yet as I'm not back on the road, but I have a good feeling.

By the way, changing 1st and 2nd synchros is no big thing on the 915, and doesn't need any special tools other than a couple of big sockets, and you don't need to loosen the shift forks like the books say.

Martin

Do you have any details of this procedure.
My 915 'box has this exact fault. I have been quoted £1500 for a gearbox overhaul.
I am more than willing to give the syncro swap a try myself. I can always hand over to a mechanic.
BTW I am in Zurich working currently, where are you?

Regards

rob