2g GSX Manual
6 puck clutch. Lightweight flywheel. ACT Xtreme duty pressure plate. Extended slave rod.

First gear keeps popping out when I try to take off in 1st gear. The pop outs started last week. I added fluid but, it didn't work.
I've read through several threads and can't find a reason. I had this happen years ago, but it went away randomly.
I've never replaced any bushings. I can move the gear into first very easy by hand I'm the engine bay and when the car is stopped.

What causes this?
What steps?
What can I adjust to help?
Is the transmission going out?

Pictures below show what some things look like in case someone can see the problem.
Please help.


Above is the part above the clutch pedal. Can this be adjusted?

Take the cable off and shift to first manually. If it still pops out it's likely inside the trans.
I recommend getting rid of the extended slave. If the clutch doesn't work without it you have other problems.


It's also been my experience that first or 2nd gear popouts are worn bearings on the intermediate shaft or worn shift forks. By all means rule out the cables, weight hitting something etc. Cables are not adjustable on 2g if I recall correctly. If there are adjustments they would be at the shifter in the car.

Thanks. I read the write-up above.
Will shifting manually without the cable and no pop outs rule out worn bearings?
I will update tomorrow with your suggestion.

I had this same issue with a trans I picked up from the junkyard although I’m fwd. 98% of the time it would pop out. Sometimes if I really slowly slipped out of 1st by riding the clutch more it wouldn’t and sometimes if I held the shifter it wouldn’t but ultimately I ended up getting another trans and that solved my issue. I put solid bushings at the trans side of the cables hoping it would help but it didn’t.

Definitely get rid of the extended rod you’re causing more harm than good in the long run.

GIB said:

Thanks. I read the write-up above.
Will shifting manually without the cable and no pop outs rule out worn bearings?
I will update tomorrow with your suggestion.

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Likely but not 100%

Agree with post 3. May end up having to replace tranny bearings, forks, and adjust bearing preloads all inside the tranny. But check all other possibilities before pulling tranny, including making sure shift cable casings are being held in place properly near the tranny (sometimes they break free or move around in the hold down brackets causing shift problems). Also undo any "skateboard bearing mod" which wears shift forks down, personal experience (read here: https://www.dsmtuners.com/threads/youre-not-a-true-dsmer-unless.528362/page-2#post-153760144). BTW shift cables are not adjustable on 2g. And if the internal 36mm shaft nuts get loose that can cause popouts/fork wear since it allows the shaft to move longitudinally.

luv2rallye said:

Undo any "skateboard bearing mod" which wears shift forks down, personal experience (read here: https://www.dsmtuners.com/threads/youre-not-a-true-dsmer-unless.528362/page-2#post-153760144).

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Damn, I had no idea. I guess I’ll be undoing mine…

pauleyman said:

Take the cable off and shift to first manually.

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This !!!!! ^

My issue was the cables

luv2rallye said:

Agree with post 3. May end up having to replace tranny bearings, forks, and adjust bearing preloads all inside the tranny. But check all other possibilities before pulling tranny, including making sure shift cable casings are being held in place properly near the tranny (sometimes they break free or move around in the hold down brackets causing shift problems). Also undo any "skateboard bearing mod" which wears shift forks down, personal experience (read here: https://www.dsmtuners.com/threads/youre-not-a-true-dsmer-unless.528362/page-2#post-153760144). BTW shift cables are not adjustable on 2g. And if the internal 36mm shaft nuts get loose that can cause popouts/fork wear since it allows the shaft to move longitudinally.

Click to expand...

I concur. I do not and have never used the skateboard bearings.

luv2rallye said:

Agree with post 3. May end up having to replace tranny bearings, forks, and adjust bearing preloads all inside the tranny. But check all other possibilities before pulling tranny, including making sure shift cable casings are being held in place properly near the tranny (sometimes they break free or move around in the hold down brackets causing shift problems). Also undo any "skateboard bearing mod" which wears shift forks down, personal experience (read here: https://www.dsmtuners.com/threads/youre-not-a-true-dsmer-unless.528362/page-2#post-153760144). BTW shift cables are not adjustable on 2g. And if the internal 36mm shaft nuts get loose that can cause popouts/fork wear since it allows the shaft to move longitudinally.

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If the end nuts come loose that should only affect 5th. Shafts cant move, they're held down by the bearing plate

*UPDATE* I just unhooked the shift cable and put it into gear manually. It did not pop out of gear when trying to move it. I tried it 15-20 times and it never popped out. I connected the cable back up and it popped out a couple of times.
You all think it is the cables?

GIB said:

*UPDATE* I just unhooked the shift cable and put it into gear manually. It did not pop out of gear when trying to move it. I tried it 15-20 times and it never popped out. I connected the cable back up and it popped out a couple of times.
You all think it is the cables?

Click to expand...

Seems pretty definitive. Look where cables attach to trans for issues.

Could be your bushings if cables are fine
If cables are shot AND you don’t want to pay for used cables you could use the K series cables.

miliman13 said:

Could be your bushings if cables are fine
If cables are shot AND you don’t want to pay for used cables you could use the K series cables.

Street Build - Red5.

DSM - K series shifter cable upgrade: 50$ As far as I know I'm the first to document and do this. I took some measurements of the cable in the car as a starting reference when searching online. You must be registered to see element. You must be registered to see element.You must be registered...

www.dsmtuners.com

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Nice! I will get those and try it.

I saw that the bushings here were shot. That bracket holding the clips on in the picture moves like crazy when I shift.
Does anyone know what these bushings are called exactly?
(I'm still searching)

White Shed Speed and DSM Machining make upgraded replacements for those bracket bushings.

Thank you all. I will get these parts ordered and update you all on what happens after the install.

GIB said:

I saw that the bushings here were shot. That bracket holding the clips on in the picture moves like crazy when I shift.

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Are those bolts loose?

My question also. Did you at least check the bolts?

Yes I checked the bolts and they are not loose. I went through all of the rubber pieces, and the cables from the engine through the center console and checked their movement.

Looks like it'll be a couple weeks before I can get the bracket piece. He has to make it still.

*Update* I've replaced the shifter cable bracket bushings, part MD723290, 4 were needed. I also removed the longer slave rod and put the stock sized one back on. It pops out of first gear much less now. It feels like the "bite" point of the clutch in first gear is still different/ faster than before (removed the accumulator). BUT when I shift from first at a lower "bite" point, the gear never pops out.
? Could I be shifting my car wrong also?

GIB said:

*Update* I've replaced the shifter cable bracket bushings, part MD723290, 4 were needed. I also removed the longer slave rod and put the stock sized one back on. It pops out of first gear much less now. It feels like the "bite" point of the clutch in first gear is still different/ faster than before (removed the accumulator). BUT when I shift from first at a lower "bite" point, the gear never pops out.
? Could I be shifting my car wrong also?

Click to expand...

shouldn't matter what shift point or load. I would try this. Shift it into first with no cables. Drive it. Drive the piss out of it. Should take you 1000ft to figure out if it's cables or the trans. Naturally you'll only be in first gear but you can go slow, full throttle, launch it if you want, etc. etc. If it pops out with no cable on it then it's in the trans.

I will also suggest new shifter bushings. They are very reasonable and will make an old shifter feel new again.
2G DSM 95-99 Shifter Bushings | DSM 3D Creations https://share.google/Y53p77x9s72FUqckB