996 TT transmission difficult to engage third

[boelem_b]

After a 1/4 mile sprint, my 996TT now is very difficult to shift into third gear. No grinding, it just feels like there is something blocking it going into gear. If I take it from 2nd to 4th and then to 3rd it is fine, but 2nd to 3rd is very difficult and slow - I have to align it exactly before it goes in.

 

I have re-aligned the cables at the shifter with the centering tool and it improved slightly, but it is still far from right. There was quite a bit of black plastic(?) swarf around the shifter area. I also checked the cable linkage points on the gearbox and it seems to be fine. 

 

The gearbox was replaced (with a new one as far as I know) at 70000km by Porsche and I am now at 84000km, so effectively it is still quite new..

 

Any ideas? 

 

[boelem_b]

I took it in to a local indie who opened up the tranny. He says it is the 2nd to 3rd synchro ring. Hopefully that's all that's wrong. He had to order the part from Germany, so I should know in about three weeks time.

[calfrank]

Hi, was the synchrro ring the problem?  I have the same issue when shifting from 2nd to 3rd as well.  

[boelem_b]

Hi, yes it was the synchro ring. I just got the vehicle back and the problem is solved. It is a 200USD part, but they have to drop the engine and strip the gearbox, so the labour makes it quite an expensive exercise. Use the opportunity to check clutch, etc. as well. They found a split airhose in the process too, so that is a good thing. Below are two photographs of the damaged synchro. The arrow shows the corner of the raised block part that has a notch in that shouldn't be there.