SOME of you guys crack me up, especially on this particular subject of 2nd gear popping out.
In the 993 Turbo, we did have an initial problem with the 'shift fork" and necessitated a re-engineering of that particular item.
However, many times it WAS exacerbated by an overexuberant "shifter", as in the human type!
We do a ton of 996 cup and Turbo gearboxes and just about every failure is traced back to hard or missed shifts.
ONCE you "knick" the syncro, especially the racing type, it's just a matter of time before "pop out" occurs.
Short shifters in particular do not cause that problem IF properly used.
Even on the track, one CANNOT "hurry" the shift.
In short-practice proper shifting techinque does wonders for transaxel longevity!
havefunshiftcorrectlydriveporsche-Mark-FORMULA MOTORSPORTS

 

I agree with you 100%.

 

nobody arguing about "whats wrong" with the tranny.. is it the synch rolls or the shift forks.... or is it due to poor driving habbits or inherant in falty design.
regional service reps have a hard on when they see a poping 2nd gear... especially if u have a 3ed party shifter. thats the point. the other one is: try to get it warranteed.
Im not trying to start anything... I'm just sharing my actual experience.... irrelevent whos right or wrong.

 

Simple solution and I would suggest that EVERYONE who has an aftermarket shifter and tranny issues do this: Switch back to the stock shifter for the warranty inspection. It only takes a few minutes to switch it back and it will minimize the headaches (hopefully).

 

yeah but some guys don't know that and they get wacked. I have heads up cause I'm really cool with the service manager.
One more thing, if one doesnt have a shortshifter... then the regional rep makes the technician open the tranny.. and then he will come to a decision that its POOR driving habits thats caused the synch rolls to mesh. I've been told this one as well... by the mechanic.

 

sometime the cause is not important & why is it so hard to get that point acrossed?

some dealers don't really care what's the cause of the problem & instead they're looking for cause to blame. u gotta give it to them some dealers have no clue what they're doing. i've seen so many times service writer freak out on aftermarket stuff it's not even funny.

aracerx,
try to explain what u wrote to a service writer who has no clue what a ''syncro'' is then u'll have a better idea. it is not important what we think here or the fact is but what they actually believe in.

 

Hey Guys,
Offering up the causes of the gear popping was my original intent, not the warranty issues resulting from said popping.
THAT said; being in the Pbusiness all my life AND working for the factory there is TRULY AND "UNBULL****TINGLY" TWO sides to the warranty conundrum!
WE ALL know many within our peer group who have been given "special dispensation" from dealer/regional factory reps on a BOATLOAD of flagrant, customer related failures AND outright abuses. Understand I'm currently an independent operation in NYC without encumbrances of standard company responses to such issues as warranty related.
In the everyday thing we do, I would say that gearbox syncro related failures inevitably fall within abuse/and or age as the majority culprits.
That said-the "company" does have certain unsubstantiated "hard-ons" for what we consider valid warranty repairs. Such as-PCCB brake failures. regards Mark-FORMULA MOTORSPORTS

 

There may be an inherent design flaw in the 6 speed. I read in a TSB about the syncros having trouble overcoming the momentum of the very heavy (large diameter) 1-2 gear set. You can speed shift an old muscle car with a Muncie 4 speed or Ford toploader for years and not hurt the trans. In the meantime I'll avoid fast shifting on my Turbo.

 

This whole discussion reminds me of the same warranty/manufacturer vs. owner situation on the E39 M5 clutches. There was alot of trouble and many needed replacement, some of which were done under warranty and some which were wholly blamed on the driver, no warranty. Our discussion was something to the effect of it is a "performance car" and shouldn't be that fragile for so many people to be having this problem. While I'm sure there were people there abusing their clutches just like some TT owner's abused their gears, all the blame can't be on the drivers. The decision is left to an all-to-random does the dealer/rep like you or what. I think the manufacturers owe it to all of the owners to THOROUGHLY look into it and then pass the information along. I doubt that happened as much as it should have.

 

Speed shift a Muncie...Dude! That's a wowzer! Mack makes a strong gearbox too!
I've driven 24 hour races with this type (porsche) syncro and not had any problems!
Can someone confirm the durability of a "muncie" carrying those kind of ponies for 24 flat out hours-that's a heap of calories by anyone standards.
I've torn down plenty of aforementioned "boxes" only to be able to really make cogent comments. Please refrain from introducing a "muncie" into our (so far) intellectual discourse on dealer/factory warranty repairs. As I originally said, the issue goes both ways.
Please don't misinterpret my comments- but- All of you know someone who F*cked up his car and the factory swallowed the repairs. ALL OF US know how screwed we were when a ligitimate correction became a nightmare, especially when they come out of the dealer 50 lbs lighter from the parts left out!
havefunshiftporschetakechances-Mark-FORMULA MOTORSPORTS