1958 T2 popping out of 2nd gear. Adjustment advice?

[Vic Skirmants]

Center the fork between the two gears. Loosen the clamping bolt and center the fork equally. I use blue Loctite on the bolt, and torque to 20 lb-ft. It looks like you found the problem. Synchro wear does not affect the position of the fork.
If after doing the above you still can't get into 2nd gear, you may be having a problem with the internal synchro pieces. Porsche re-designed them after trans #50000 in late 1961 to cure a problem.

[Mark Pribanic]

Didn't work. Tried centering, moving all the way to left & then all the way to the right. Still only engage part of 2nd. Could the shift rail need to move in?

[Mark Pribanic]

This is the shift rail all the way left to engage 2nd. The fork was also 20lb all the way left on adjustment.

[Steve Hatfield]

Like a lot of others here, I'm following this with great interest and much admiration for your guts.
Neptune Beach is not that far from Fort Walton so if I ever encounter tranny issues, I'll be right over.

[Vic Skirmants]

Did you loosen the bolt and try to move the fork and sleeve further? If you did, and the sleeve would absolutely not fully engage the synchro hub teeth, then you do have the dreaded 716 internal synchro bit malfunction.

" The fork was also 20lb all the way left on adjustment."
I don't really understand that statement.

[Mark Pribanic]

Not sure if I posted when I lost second gear. My clutch cable broke, I was in a bad neighbor hood late at night and tried to start in second gear to get to a more safe place to wait for AAA. When I went to start the car it bucked about five times, I shut it down. Tried it a second time. Bucked about five times and shut it down. Replaced the clutch cable a few days later and second was popping out. Hopefully that gives some additional insight.?

[Mark Pribanic]

What I meant was the fork can be adjusted left, center and right on the shift rail. I tried all three. I thought if it was in the far left position it might engage the gears.

[Mark Pribanic]

Ok, so I have another question...can the 716 selector fork be used in a 644 gearbox? The current gearbox was put in when my original 644 gearbox broke the 3/4 shift fork, locking it into 4th gear. In other words can I use the 716 shift rails and forks in my 644 gearbox?

Thank you for all your help Vic and others

[Mark Pribanic]

Found the answer to my question. Vic answered it in 2011, when I put this gear box in.

[Mark Pribanic]

So I put the 741 selector forks on my original 644 shift rails. Four years ago my 3/4 shift fork broke and left the box jammed in 4th. Was able to go through all the gears good. Gonna bolt the gear box back up, swap my backing plates, drums and hoop back to the 644 and should have it in by tomorrow night. Gotta still cut the grass tonight. Fingers crossed!

[Martin Benade]

While the gears are out, be sure to inspect the differential carrier very closely for cracks, at least the kind you can see. Maybe there is a phone app to magnaflux? I am impressed at the amount of work you are getting done in a short amount of time. You must be younger than me- more drive and less patience. And you need your car back on the road!

[Mark Pribanic]

Hi Martin, yup, very motivated! I werk best under truncated timetables. I've been invited to participate in a 50 Porsche outlaw rally from LA to Rennsport Reunion V in four weeks. Don't want to pass this opportunity up.

[Mark Pribanic]

Like a lot of others here, I'm following this with great interest and much admiration for your guts.
Neptune Beach is not that far from Fort Walton so if I ever encounter tranny issues, I'll be right over.

Thank you Steve! Your welcome at my house in Neptune Beach anytime!

[Walt Nolte]

I have been following this thread with great interest as well. Not meaning to hijack the thread, but I have a similar issue as Mark and my car, although a 59, was built in 58 and is also Meissen Blue with a 644 transmission. It pops out of second gear on spirited acceleration, 50% or more throttle. Several years ago the transmission was worked on. New carrier housing and needle bearings. As I am away from the car and my records I do not have a complete list of replacement parts. After this work, the second gear shift point never seemed to seat into location on shifting and would occasionally pop out. So I have been careful to pull the gear shift as far into the shift point as posssible. Over the last few months, especially after spirited driving, the condition has worsened. Like Mark, I was hoping that adjustment and relacing the shift linkage bushings might solve the problem. I don't drive the car enough in fourth gear to know if it is a problem as well. As I live in the middle of nowhere and do not have the skills and tools to pull the engine and transmission I am hoping that I do not have to pull these like Mark is doing.

Any thoughts would be appreciated.

Walt Nolte
59 A Coupe
Montana
Montana

[Mark Pribanic]

For those following this thread. I spoke with Vic Skirmants before I bolted the intermediate plate, gear cluster & nose cone together.bin my original 644 gearbox. Swapped the hoop, backing plates and brake drums. Then put new axle boots on. The 644 box is going in tonight.