986S 02 Gearbox problem - 2nd gear grinding

[Archimedes]

Just to update anyone that is following this thread, finally, after three weeks, I've now got my car back complete with a new gearbox and reversing light switch - thankfully all covered by Porsche's warranty. We've had a few very cold mornings this week and, touch wood, so far the gearchange is now as it should be - positive and slick.

According to the service manager, the 2nd gear synchromesh was failing and on its way out. He mentioned that after stripping it down it was considered too costly to rebuild the 'box, hence the new unit. To the dealer's credit they provided me with a 2.7 987 Boxster with 1000 miles on the clock as a loan car which went some way to negating the grief with my car.

[Paul]

I have the same issue on my 01 5 speed when its below 0 degrees outside. I just shift from 1st to 3rd until the car warms up.

[Snipped]

I've had/have the problem on a 2001 S 6speed as well, at 55k miles.

3-2 sometimes was impossible, and 1-2 would grind. First attempt to fix was a motor mount, which completely cured 3-2, and mostly fixed 1-2 when warm, but not when cold. Over time, 1-2 got worse again even when warm.

Second attempt was to readjust the shifter cables, which almost cured the problem when warm, but not when cold. 3-2 seems fine; 1-2 is the problem.

I shift first to third when it's cold, cold being 40F here in northern california. . .the synchros are clearly not doing their job sufficiently. I'm pretty sure I'll be having the box ripped into before too long. The problem really detracts from the fun of the car for me--it gets in my head that I'm never quite sure if I can get a clean 1-2 shift when I want to.

I'll post again if/when I do get the 2nd gear synhro replaced.

[turbo23dog]

I have a theory about notchy shifting on 6 speed Boxsters.

I too suffered from not being able to shift into 3rd gear when the trans was cold. It was also notchy going into 4th all the time. 2nd Gear was occasionally notchy and sometimes it felt as if the gearshift lever was not making the full travel into the 2nd gear.

In an unrelated thread, I asked for opinions regarding a minor shudder under light acceleration through ~3K rpms. Several folks recommended I check my front engine mount. Sure enough, the front mount rubber was torn completely through and this on a 00S with 28K very easy miles.

BOTTOM LINE: replacing the front engine mount seems to have completely changed my shifting feel in all gears for the better.

Since you can't see the engine mount without removing it, I wonder just how many Boxster owners that have reported shifting problems have a bad front engine mount.

I also wonder, OUT LOUD, if there is any possible way that the stress on the mechanical equipment of engine and trans from a bad front engine mount could cause other problems, say for example a possible connection to rear main seal leaks.

YMMV

[aBsOlUt]

Welcome to the nightmare of my life.

How many times do I drive this car which I love but the fun factor drops below zero with the gear changing. Especially from 1st to 2nd.

Well, I had enough, I've replaced the mount as well and it seemed to fix the problem but only temporary. I used to think its me as a driver but no way. Gear changes are too harsh and they almost feel to slowly break the car apart.

I went to the dealer and talked to a mechanic for 45minutes about the story. I got a phone call that they are replacing the transmission, especially for the 2nd gear but during the process they will fix everything else.

This is going to take a week and I am praying the gear shifting will be a bit smoother so I can enjoy this car the way it was meant to be enjoyed.