so, the engineer in me is curious about the actual defect that causes this problem. I've searched the threads but never found a detailed explanation.
Is it from parts that were improperly made or installed? Once fixed, is the repair permanent .... or does it come back eventually?

krswen

 

the problem is in the dogs on the gear they are weak and get rubbed off with couple bad shifts under power.

Gbox had some mods they do to the gears and im sure the other tranny companies have found similar fixes modifying the gear set to prevent this but it would involve a complete tear down of the transmission.

 

Grinding 2nd gear is the cause.
Detent mod is a bandaid fix that will work pretty well for a while.

 

Transmission rebuild with GBox works every time. Do you have an active warranty?

 

Above posts list the 2nd gear pop out issue due to abuse.

There WAS a defect in some transmissions that PCNA calls "assembly fault".

They have a TSB that is a photographic 'damage catalog' with a differential diagnosis on the two causes... 3/1/2006 manual Transmission Binder 3 "damage catalog".

 

If you go with a tranny rebuild, I would strongly consider going to a 997 TT main shaft and first 3 gears. You get a stronger gear set and taller gears.

The Gbox detent is a good preventative measure as is avoiding hard 1-2 shifts (and powershifting). The GBox detent has been proven to be at least a partial fix in that it reduces an already popping 2nd gear.

I wonder if the 997T Tranny is a bolt in?

 

The problem lies in how the gears dogs were machined/designed /heat treated

The only forsure fix is machine work/better designed part

The detect kit is good but it won't completely stop it

 

I was looking at doing the Detent fix since mine pops out of second on rare occasions and don't want it to get worse. Basically I've got to be at high RPM in second and let off the throttle abruptly. Being on a decline makes it more likely as well. How hard is doing the Detent? Anybody have any experience with it?

 

https://www.6speedonline.com/forums/...insurance.html

 

Nor Cal,

I had the detent installed, not because I had the 2nd gear pop out occuring, but because 2nd gear was hard to go into and it never felt like it seated in as deep as the other gears. Since the install, it goes in very deep and secure feeling - much easier and smoother, too. I have a feeling that with the occasional pop out you described, if you install the detent, it would not happen any longer. It's a very inexpensive part and certainly worth a try. I think it improves the transmission action and would recommend it to anyone, regardless of issues.

 

where can one purchase?

 

http://www.gboxweb.com/

Ask for Eric