What should I check for a tranny that keeps popping out of 2nd?

[kristmen]

I have a 91 TSI with a 92 style awd tranny in it.

I've put about 4000 miles on the tranny and recently its started to pop out of second gear.

It really feels like its not going all the way into second but for the first 3000 miles it was fine. This has only started recently. First it just did it once or so a week, then daily, now a few times a day.

Not sure what to check. Jon at TRE adjusted the clutch for me a couple thousdand miles ago so I would think that would be fine still. Ming said to check the shift cable brackets to make sure it had not come loose and it hasnt.

As you might have guessed this tranny was rebuilt by TRE around 4000 miles ago and it has not been beaten on yet.

[evil~eagle]

Sounds like the shift fork to me, I had that happen to me once, ended up being the lock pin that holds the shift fork on the rail, it was back all the way out, it allso may be your hub and slider, but if you can not find anything on the outside of the trans (IE cables, cable holders ect.) then I would have to say you would have to pull the trans apart and see whats going on..

[anconover]

possible that the bushings in the cable brackets are bad. In which case u can losen the upper 2, and actually pull the cables a little bit forward so u can drop back further into 2nd gear. Its happened to me with 1st.

Also could be one of the 3 balls in the front of the tranny (3 bolts with springs/bb's). Ive seen a bad spring cause a similar problem.

Play around with the cables/adjustments etc before assuming the worst.

[kristmen]

Well the forks are brand new EVO III forks and they do something diffrent with the way the pin them so the pins can't move and cause problems like spoken about above.

I'm thinking the problem has nothing to do with the tranny. I think its going to be somewhere in the cables or shifter.

This is a fresh TRE rebuilt tranny.

[anconover]

only 1 way to go find out. go play around with the cables etc...

[kristmen]

Thats the plan. I'm sorta lazy though. I'll just sit around and bitch about it for a few more weeks ;P

I'm sure thats all it is though after doing some research.

Hell even if its not, the tranny is under warrenty by TRE and I know those guys pretty good.

[mavisky]

If it's popping out of gear and the cables are adjusted properly it means that the bearings inside are actually allowing the gears to move around which is causing it to pull itself out of gear. I'm betting it does it whenever you let off the gas. In my car it would hold gear while I was on the gas, but as soon as I let off it would pop back to neutral. My bearings were shit inside.

[evil~eagle]

If it's popping out of gear and the cables are adjusted properly it means that the bearings inside are actually allowing the gears to move around which is causing it to pull itself out of gear. I'm betting it does it whenever you let off the gas. In my car it would hold gear while I was on the gas, but as soon as I let off it would pop back to neutral. My bearings were shit inside.

Yeah see my tranny was completly opposite, it would pop out of gear as soon as you hit the gas, would stay in gear coasting lol.

[kristmen]

If it's popping out of gear and the cables are adjusted properly it means that the bearings inside are actually allowing the gears to move around which is causing it to pull itself out of gear. I'm betting it does it whenever you let off the gas. In my car it would hold gear while I was on the gas, but as soon as I let off it would pop back to neutral. My bearings were shit inside.

Gas doesnt seem to have anything to do with it. Only does it when I catch second and hit the gas and let out on the clutch.

This bearing you are talking about. About where in the tranny is it located? Could it be causing a grinding noise that sounds like a throw out bearing?

I've had a grinding noise for ages and when I took the car back to TRE they said they were 100% the noise was NOT inturnal tranny noise but were not sure what it was. Someone else said it was my TOB.