Cost to repair 2nd gear pop-out
 

I am at the point where I just don't want to deal with it any more. I had a PPI done and they missed it, I missed it(not knowing that to REALLY catch it you roll on 2nd on a decline) and have been driving on it for over a year... I know it doesn't do any more damage to any other internals but it's just annoying as all hell. It doesn't happen too often but it does happen.

At this point I know a lot of people have this repair down to what's needed to be done so I don't want to hear that I need a whole new transmission etc. I understand that I just need a new 1st-2nd sychro so I am hoping I can get a pretty accurate cost someone on here has recently paid.

Thanks in advance and aside from this one issue the car has been awesome, every day that I drive it I know exactly why I bought it and hope to never have to sell it... for the money I spent on it and they reliability it delivers I can't imagine another car delivering more in the cost/performance/driver-happiness formula.

man, do i empathize. it's one of those things you forget about until.. ARGH downhill 2nd gear coasting/d'shifting.

you're right that 1st/2 gears and synchros *should* be all you need to repair it. BUT make SURE they re-shim it to the AMMENDED specs. not the original OEM specs the tolerances of which were ammended, hence the factory supplied different shims. essentially the gear stack placement needs to be altered somewhat. at least that's my story from having the master tech at la's largest dealership rebuild it. twice.

gt gears and eric at gbox would know this already. you might also inquire at bbi? down there assuming they are near you. as gt gears and gbox are not. i think you're looking at at about $3k+ but could be a bit more? sorry, mine was warranty work but thats ballpark

again, empathy. most annoying issue. hand on gearshift always downhill. wtf.

$2,000-3,000 parts and labor if you can find someone that is familiar with the process...

Sorry to hear about your troubles, OP. Good luck with everything.

To those in the know: how steep of a grade are we talking about here to test for this issue? I've done some aggressive acceleration/deceleration in 2nd to test for this and found nothing (knock on wood), but never really on a significant slope.
-V

Who told you you need 1st and 2nd synchro? I had zero pop out issue until I had my clutch main bearing fail on me. I had it changed and 1st and 2nd synchro replaced as preventative measure (big mistake)! Once this was done my car developed pop out issue. As explained by 02996ttx50 it's all about tolerances & specs. Mine pop out issue was resolved by gbox detent (thank god). Give it a try first. If tolerances are only slightly out the chances are it will work. Good luck.

there's no definitive *test* for it, per se. but if you have *it* it would have revealed itself to you simply going downhill in 2nd. nothing more special than that. the first time it happens is painful. mine actually popped out going UPhill once. once the dogring is sheared? forget about it. fix it or live with it.. or if you're VERY fortunate ( like terminator is ) the gbox detent can save you if the damage to the dogring/synchro is minimal. it's just not one of those things that gets better over time.

the only mistake ( i'm guessing here of course ) was that when they did replace your synchros? they replaced them and spec'd the trans to ORIGINAL factory specs.. no? that SHOULD be the only reason one has a problem after fully replacing parts.. and is exactly why i had to have mine re-built twice! to shim it correctly X # 2.

what i got from the OPs post was he was simply aware that the second gear synchros are what is generally replaced to repair the 2nd gear popout.. and that is generally correct. as you know.

I agree but;

what I am saying is my synchros were not bad. Some cars just had a bad tolerance to begin with. Pop out does not necessarily mean bad synchros. Some had pop out issue on new cars / new gear boxes.

OP go to gbox web site and read some good info there. Detent might help if you problem is "small".

wow. i'd never heard that. i was told it can happen from one barely missed shift. enough ever so slightly round the dogring and synchro that will exacerbate the intolerance inherent in the original setup. but yes, again. incorrect tolerances, contribute; bottom line.

the good news.. is we have both emerged from *it*. i will say i am pretty damn mindful of 1-2 shifts these past few years. but i double clutch a lot anyway..bad old habit.

I already went the Gbox Detent route and it didn't help, my understanding was if the problem exists then you can't undo it- the proverbial 'you can't unscramble an egg'.

I will get it done thru BBI, I just want to know what to expect. Your feedback is helpful, I appreciate it

That's good news brother, it can happen on the slightest decline and if you've never experienced it then I'd say you are home free!

you're welcome..and thanks. it's a royal PITA no doubt, but you know more about it than when i dealt w it. man, did i get a runaround at first from porsche. they were initially "deny deny deny".

i'm sure bbi will nail it. seriously..GL with it.

What sucks is I KNEW to look for 2nd gear pop out prior to purchasing and did a number of roll downs in 2nd gear looking of it, but I never did it on a decline. I was also pretty bummed that the shop that did my PPI didn't pick it out but again it doesn't do it all the time.

The forum here definitely did their job in educating me and also for not freaking out when it happened. I know when it first started happening people lost their minds thinking they had to do complete trans rebuilds/replacements etc.

I will budget for an extra large bill at my 60k service and have them do that and the 2nd gear fix at the same time.

yeah.. kinda insult to injury type stuff. i hear ya. imagine how i felt! i got mine SOLD to me that way as a cpo car. i suppose it made it a bit easier to get em to pony up.. but not at first. they wanted to "type 2 overrev ecu read" me to death. but i wouldn't lay down.
i counted their hours down on the ecu dump subtracted from my date of purchase and said "maybe a test drive a**h*les". fix this ****.

there's a point in here somewhere about being an informed consumer.. but your situation couldn't be helped. there really is no way to properly diagnose it.. and it doesn't happen every time.. until it gets baaadd.

i spent $8,800 to make the repair. you have 25 labor hours to R&R the gearbox alone...