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Check your enginge mounts carefully for damage.
Posted by GregD (more from GregD) on Tue, 3 Sep 2002 16:09:42
In Reply to: 5-speed transmission popping out 2nd gear, john t franklin, Mon, 2 Sep 2002 19:25:11
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and the shifter assembly too. Other than that, the internal causes are, as Justin points out, worn pinion bearings that let the mainshaft walk back and forth when power is applied and released, and a worn shift fork. The 2nd gear side of the 1-2 fork takes the hardest beating and invariably is the first to wear out. Synchonizer wear has no contribution until the cone is striking the teeth of the synchro sleeve. By the time that happens, it will be grinding so horribly that you will lose the will to keep driving it. A worn fork is the one that can be "lived with". Unfortunately, holding it in gear only accelerates the wear on it. Like Justin said, start thinking about what you will do if it's the beginning of pinion bearing failure as it will let you know in a month or two. The 3/4 fork takes little wear so if it starts popping out of either of those, you have bad mounts or worn pinion bearings.
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