Nicking 4th gear

[Tyson Schmidt]

Originally posted by dmarv
OK, I looked at the reverse lockout again and here is what I found. When shifting into 5th, I do not have to move the lever over to the right enough in the neutral gate to place the tab on the gear shift lever to the right of the tab on the carrier plate. The current adjustment of the coupler allows me to shift into 5th while the tab on the gear shift lever is to the left of the tab on the carrier plate. I do not believe this should happen. I should only be able to shift into 5th when the tab on the lever is positioned to the right of the tab on the lock pawl carrier plate. If I push the lever over to the right (more than I normally do) so that the tab on the lever is to the right of the tab on the carrier plate, the lock pawl operates perfectly and I do not knick reverse. Looks like I need to adjust the coupler!

Glad you got it sorted out!

I hope you have an easy time adjusting. Good luck!

[Tyson Schmidt]

Originally posted by dentist90
Reverse lockout works great... played with shifter before re-installing. Problem is if I set up 5th so that lockout cam slips in behind shift lever I nick R on the pullback to 4th, even before it reaches neutral plane. Even if I keep pressure to the left (toward 3-4 plane) while shifting out of 5th I get the grind. Shifting while not moving is fine, but the gears aren't spinning then. Frustrating! I had to move my neutral plane just the opposite of what you were suggesting to stay out of trouble, ie move neutral plane closer to R than 5th so I could get shift lever unlocked from the shift tab and over to 4th plane before R shift fork starts to move. I tried it the other way and I couldn't go from 5 -4 at all. Had to stop the car completely before I could get out of 5th without grinding R! Luckily no traffic. Right now It's functional, but only about 1/3 of locking tab is overlapped in 5th and lockout cam doesn't click in. Transmission internal shift distances just don't seem to jive with shifter design, but it is the factory SSKit. R being non-synchronized is pretty obvious as there is immediate clashing if I begin to pull back into R zone... no balking here! 1-4 shifts are a breeze no matter how I have adjusted, just moves the shift knob either closer or farther away.

Sounds like the shift fork for 5th/reverse was misaligned by whomever rebuilt the trans last.

5th/reverse is different than the other shift fork adjustments in that you want the slider to be very close to the 5th gear synchro, and a good distance away from reverse. Maybe someone centered them between the two like is done for 1-2 and 3-4.

Just a guess.

[dentist90]

Well Tyson, I think you may have hit the nail on the head. I had queried in a previous post whether there could be something internally wrong. I have only seen pictures of disassembled tranny and it looked like shift forks could be clamped anywhere along the shift rod. This would make perfect sense. Unfortunately I'm not ready to drop the tranny right now just for that adjustment. This adjustment of the 5-R shift fork only involves taking off the front cover, perhaps? I think slightly moving the shift fork toward 5 would make all the difference. I'll see if there have been any posts on aligning the shift forks after I consult Bently.

[dmarv]

I adjusted the shifter coupling last night. It was very easy and straight forward. I first adjusted the coupler according to the factory Porsche workshop manual. When I took it out for a test, I couldn't get 5th gear, in the 5th position I was in 3rd. Readjusted a couple more times and my problem went away. Thanks for all the help!

[Tyson Schmidt]

Glad to hear it dmarv! Not so tough, was it?



Dentist90, yes, you would only need to remove the nose cover, and crack loose the pinch-bolt for the 5/R shift fork. Then just slide it towards the 5th synchro until the tips of the dog teeth are just ever so slightly past the edge of the synchro ring, then tighten the pich bolt.

[dentist90]

Thanks for your advice, Ty. I think I have a new project on my list of to-do's. Cheers!