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ianp · 09-10-2009, 04:40 AM

Just joined this forum and seen your post. I also have a 2003 Boxster S bought with 12k miles. 2nd Gear jumps out just after clutch is released. I have done some research on this and most helpful explanation came from Baz at Hartech Bolton? UK. If I've got the explanation right, the problem can be caused by worn 2nd gear synchro, but can also be caused by 2nd gear not engaging fully due to wear/tolerancing on the actuating mechanism. I'm told the gear shift moves the gear part of the way into engagement and the 'slick shift' mechanism takes over and moves the gear fully home. Wear, combined with wide tolerances can lead to the gear not being moved far enough into engagement by the actuating machanism (springs,balls etc) and the gear pops out when load is applied. I have partially overcome this by moving the gearstick 'positively' into 2nd gear and holding on to the stick for a moment.
Many gearbox rebuilders are happy to change 2nd gear and synchro etc but this may not be the root of the problem. Steve at Sports and Classic also very helpful
Good luck if you haven't already fixed this. I've also had very badly corroded discs and noisy rear RHS wheel bearing.

09-10-2009, 04:40 AM	#6
ianp Registered User Join Date: Sep 2009 Location: United Kingdom Posts: 1	Boxster S 2nd Gear Problem Just joined this forum and seen your post. I also have a 2003 Boxster S bought with 12k miles. 2nd Gear jumps out just after clutch is released. I have done some research on this and most helpful explanation came from Baz at Hartech Bolton? UK. If I've got the explanation right, the problem can be caused by worn 2nd gear synchro, but can also be caused by 2nd gear not engaging fully due to wear/tolerancing on the actuating mechanism. I'm told the gear shift moves the gear part of the way into engagement and the 'slick shift' mechanism takes over and moves the gear fully home. Wear, combined with wide tolerances can lead to the gear not being moved far enough into engagement by the actuating machanism (springs,balls etc) and the gear pops out when load is applied. I have partially overcome this by moving the gearstick 'positively' into 2nd gear and holding on to the stick for a moment. Many gearbox rebuilders are happy to change 2nd gear and synchro etc but this may not be the root of the problem. Steve at Sports and Classic also very helpful Good luck if you haven't already fixed this. I've also had very badly corroded discs and noisy rear RHS wheel bearing.