09-03-2020, 03:46 AM
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#1
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Registered User
Join Date: Aug 2019
Location: Toronto
Posts: 103
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What Grinds my Gears?
Hi folks, I have an issue on my 2003 S where when i change into 2nd gear I sometimes here a bit of a grinding noise.
Just wondered if anyone else experienced this before and I would imagine on the extreme end it could be the gear syncro's.
Other possibilites are linkage maybe? Are there any common wear items in the linkage that could cause it?
Thanks!
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09-03-2020, 04:41 AM
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#2
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Registered User
Join Date: Sep 2016
Location: Stow, MA
Posts: 918
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This is a common problem with the 6 speed transmission. It is caused by excessive wear of the synchromesh and also the detent being a bit weak. If you catch it early you can keep it going longer by installing an aftermarket second gear detent that holds better.
Once it starts popping out of gear when warm you have no other choice than a rebuild.
__________________
2004 Boxster S Silver - FUNTOY
2002 Boxster Base Guardsy Red - FUNBOX
1987 Caterham Super 7 1700 Supersprint
2009 Mercedes Benz CLK 350 convertible
1941 Dodge Luxury Liner Coupe
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09-03-2020, 06:37 AM
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#3
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2003 S, Arctic Silver, M6
Join Date: Oct 2014
Location: Winnipeg, MB, Canada
Posts: 1,348
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My 03 S has a similar issue especially when cold. I usually double clutch going into second for the first few shifts and then things clear up. Downshifting from 3 to 2 sometimes grinds if I haven’t properly rev matched but not often.
PS it is definitely the synchro confirmed by my indie. He said live with it for now or pay mucho bucks. I’ve learned to live with it.
Last edited by paulofto; 09-03-2020 at 06:40 AM.
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09-03-2020, 07:01 AM
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#4
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Registered User
Join Date: Dec 2009
Location: Orange County, CA
Posts: 1,848
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Servicing the gearbox with fresh OEM oil may help your synchros to work better
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09-03-2020, 09:56 AM
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#5
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01 Boxster S
Join Date: Jun 2020
Location: Windsor
Posts: 14
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This happens to mine as well when cold only. First few times going into 2nd, then its fine the rest of the day
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09-04-2020, 05:22 AM
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#6
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Registered User
Join Date: Sep 2006
Location: Omaha
Posts: 2,870
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How tough of a job is it to change the synchro? Is it a DIY or something best left to an expert? Asking for a friend. 
__________________
GPRPCA Chief Driving Instructor
2008 Boxster S Limited Edition #005
2008 Cayman S Sport - Signal Green
1989 928 S4 5 spd - black
1987 928 S4 - Granite Green Metallic (Felsengrun)
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09-04-2020, 08:44 AM
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#7
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Registered User
Join Date: Oct 2008
Location: O.C. CA
Posts: 3,709
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Quote:
Originally Posted by Gilles
Servicing the gearbox with fresh OEM oil may help your synchros to work better
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Not enough for the hassel on mine.
__________________
OE engine rebuilt,3.6 litre LN Engineering billet sleeves,triple row IMSB,LN rods. Deep sump oil pan with DT40 oil.
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09-04-2020, 08:50 AM
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#8
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Registered User
Join Date: Oct 2008
Location: O.C. CA
Posts: 3,709
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Quote:
Originally Posted by husker boxster
How tough of a job is it to change the synchro? Is it a DIY or something best left to an expert? Asking for a friend. |
It requires a big press to do it right, I sent mine to California Motorsports in Arizona where they installed their modified schncro & improved detent & billet shift arrester.Now 2nd gear shifts easier than 3rd!
__________________
OE engine rebuilt,3.6 litre LN Engineering billet sleeves,triple row IMSB,LN rods. Deep sump oil pan with DT40 oil.
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09-06-2020, 11:29 AM
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#9
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Registered User
Join Date: Aug 2019
Location: Toronto
Posts: 103
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Thanks to all that responded. I think first I will attempt to change the gear oil with OEM or a suitable aftermarket one and go from there.
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09-06-2020, 05:56 PM
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#10
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Registered User
Join Date: Sep 2006
Location: Omaha
Posts: 2,870
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Quote:
Originally Posted by 9864ever
Thanks to all that responded. I think first I will attempt to change the gear oil with OEM or a suitable aftermarket one and go from there.
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Good luck. I've recently changed mine twice since the grinding began and new fluid didn't improve things. It certainly needed changing the 1st time since it was still the original and I'd done quite a few DEs. Decided to change the 2nd time to try Motul but that didn't help either.  Hasn't gotten to the point of popping out of gear and it only grinds on the 3-2 shift, so I avoid that as much as possible.
__________________
GPRPCA Chief Driving Instructor
2008 Boxster S Limited Edition #005
2008 Cayman S Sport - Signal Green
1989 928 S4 5 spd - black
1987 928 S4 - Granite Green Metallic (Felsengrun)
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09-06-2020, 06:37 PM
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#11
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Damn Yankee
Join Date: Mar 2013
Location: Dallas
Posts: 1,117
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Quote:
Originally Posted by husker boxster
.... and it only grinds on the 3-2 shift, so I avoid that as much as possible.
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Terry,
Have you tried double de-clutching on the 3-2 downshift? It's a lot slower, but sometimes it alleviates the situation.
Just my personal experience....
TO
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