Hi guys.
I know the thread is a bit dead, but I hat the exact same problems as described.
My car is a 2003 Boxster s (6-speed)
As Kurt described the gear crunched (sometimes) when shifting to 2nd gear especially when cold. It was like it would not engage completely into 2gear. However it felt like shifter it would go further down, but when I let go of the clutch it crunched. After I hit the clutch again, there was normally no problem shifting all the way.
The first thing I did was to find a used 987 Shifter on ebay and readjust the linkage. This did not help with my grinding. But gave a better (shorter shifting).
My next step was to remove the gearbox. And handed it over to a gearbox specialist. He opened it and assured me that all looked normal for a car with 40.000 miles on it. But as the gearbox any way was apart, I told him to replace the synchro rings for the 2nd gear.
After installation I filed the gear box with Valvoline 75w90 GL 4/5 oil. Still no improvements! And I was starting to get frustrated!
As my last attempt I tried to experimented with oils; tried another (no name) oil 75w90 still with no luck.
Last week I replaced the oil with Castrol’s SMX-S 75W85 GL3 oil. In Europe I paid 60$ per liter! So round 180$ for the 2,8L in the gearbox. But it was really worth every cent! The gear box really works perfect now!
The oil is made for some made for some Ford gearboxes, so I’m sure there must be cheaper alternatives out there and most properly the SMX-S (if available in the us) is cheaper over there as well.
I hope this helps the rest of you guys in the same boat.
Andy