Jumping Out of Third Gear


Transaxle

Stillen in Costa Mesa,CA. 714-540-5566 may still a transaxle tach. They did install 3.90 gears in the transaxles.
 
Did you ever determine what your second gear issue was? Mine has third gear doing exactly the same with regard to acting like neutral. I have not been able to get it to re-ingage in gear though as you have. I have acquired the entire GT service manual and it goes down to Aaron Scott next week to determine if linkage or synchro or gear issues. Stillen had similar third gear issue and repaired by re-welding the synchro to the cast gear. Would appreciate any update you have. I also have a new transaxle ready to ship if necessary.
 
ALLRYZE said:
............it goes down to Aaron Scott next week to determine if linkage or synchro or gear issues.
Click to expand...

Who is Aaron Scott?
 
Aaron builds high end engines for race cars and specialty vehicles. He was recommended to me by a trusted friend, (has his own dyno), upgrades GT engines with exhaust, pulley, cooler modifications... has rebuilt other GT engines who have melted their pistons with add-on turbo's, etc. He has access to a well qualified transmission pro and a shop that can CNC parts if necessary since no help from Ricardo or Ford. We will know more about my issue by the end of the week. If you would like his contact info, I can get it to you. I have been searching for a month to find the right person to fix my GT transaxle issue. I live in Atlanta but paying $$ to have it hauled to him as he has all the right criteria, understands the value of these cars and truly knows more than anyone else I have spoken with.
 
Please keep us posted on how this goes. Having someone that can work on trasaxel internals would be good to know.
 
I would think transaxle parts are easier to get than you might initially suspect... the transaxle blueprints are available online here and Ricardo made this transmission for Audi too (although the casing was modified to fit Ford spec). I can not confirm anything but I would think a little research might net the right part numbers from Ricardo? Othwise fabrication is the way to go :(
 
All of these problems sound like the counter weight problems people have mentioned before.

As a side note the cables that run between the motor and intake manifold got hot and melted on my GT. that caused the shifter to be slow to return to neutral position and a bit choppy elsewhere. I don't want to send you off chasing another rabbit but you migh check for smooth movement while your monkeying around with it.
 
Will definitely update you in a few days. It gets picked up thursday, arrives Friday. Transaxle will be out as soon as they confirm it is not a shifter linkage issue. I'm seldom that lucky.
 
Thanks Fubar. We've visually watched the external movement and unfortunately appears normal. They plan to disconnect cables and try third gear manually before bolts begin to move. I'll keep you guys posted shortly. If you find a four leaf clover please Fed X it to Atlanta. Might be helpful,
 
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Good luck
 
I have a similar problem with third gear, but it doesn't jump out by it's own, needs a gentle shift towards neutral position to come out. I have done some adjustments on the gear linkage cables, but no improvement.
 
Stay tuned. My box gets opened tororrow or Thursday after a thorough test of the linkage. All signs are pointing to a previous other car failure where 3rd gear "brass" synchronizer separated from the "steel" gear to which it was electro welded. This allows the shifter to remain in 3rd gear pisition but the gear spins freely since no longer attached to the syncro When the drain plug comes out we are hoping for little to no metal and if we are correct, hopefully we can re-weld the two components back together. A new transaxle is awaiting order should this not be the case and new parts not able to be reproduced or located via alternate sources.
 
Good luck and keep us posted.
 
Insider info!

Hi,
Here is some important info that should be shared.
I found back a statement which I received some times ago from the RICARDO gearbox production manager Adrian Turner:

"The two recognised problems with the trans were Output Flange Retaining Bolt failure and 3rd Gear Loss of Drive. The Flange problem is quite complex but resolved on all of our units. 3rd Gear failure is simply a failure of a weld, poorly done in production on a small quantity of gears and, again, fully resolved in our rebuilt units. The normal failure mode was a complete loss of drive in 3rd gear within a very small mileage and as a consequence, I would guess we’ve seen all of the weak ones now as most cars will have passed this point in use. This is also the basis of the “less than 500 miles” comment as all of our returns were known to be very low mileage examples (the vast majority failed at the factory on test).

Your current problem certainly does sound like a linkage adjustment issue. It’s not related to the “loss of drive” problem in my opinion. There is a concise setting procedure for the cables which Ford dealers should have access to."

So I will try more different adjustments to my gear linkage cables.
 
Pro_GT_driver. Thanks for the information, Really, All to often it seams like we never get the "Rest of the story"
 
The weak third gear weld (brass synchro to steel gear) was exactly a problem in a GT that was repaired at STILLEN. They were kind enough to supply me with that detailedinformation and we are expecting (hoping) the same on mine. They also provided digital photos of the failed weld. If, and I do say "if" that is the problem with mine (and I have not spun it enough to cause damage) we plan to re-weld with the electron beam welder as they used. My car does have 4,200 miles but previous owner drove it very carefully. I DID NOT. I was under full throttle in third above 130 when it let go. No noise, no gear teeth coming apart, absolutely the most unusual loss of a gear that Ive ever had and I have toasted several GM munches over the years in big block Camaros and Corvettes. I knew I had problems by the sheer noise and the fact it shredded them internally and no gears left. My GT has all other gears fine. It's been delayed at the shop but I'll share photos and details in the following week once it is out. Several of you have sent PM and happy to share my results. Thanks for the comments from Ricardo. I had no luck getting a return mail.
 
Sorry... Muncie (transmissions) Not munches. Dang IPhone.
 
Pro GT, Thanks for sharing. It is definately nice to hear your comments direct from Ricardo and those from Stillen. I realize you were addressing the originators linkage issues but you just gave us hope we are on to my problem. I wonder if I might have some recourse with Ford/Ricardo since apparently this is an admitted manufacturing flaw. Thanks again.
 
So much for our crystal ball guess we had internal 3rd gear separation. Transaxle was removed and all internals are perfect and no synchronizer/gear issues as suspected. Trans was reassembled and then inspected with internal camera as it was manually shifted at transaxle (still out of car) and functions perfectly. New STILLEN clutch and exhaust going back in and further inspection of linkage and cables appears to be the remaining culprit. Hard lesson but no need for new transaxle and have opportunity to mill slightly burned flywheel before the new clutch. As soon as Aaron chases down shifter issues and I will update for anyone interested. I will post photos of the ongoing work in hopes it can help some of you with similar issues and the ultimate problem and it's fix
 
Interesting mystery. I am relieved for you but understand the disappointment too.

Could you have used the camera before removing the transaxle?

This may be a good opportunity to install the Short throw shifter if you do not already have it in.
 
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