92 535 5spd - Pops Out of 1st Gear

[talltorontoguy]

Hi all, I posted about this in the spring and didn't get much of a response so thought I would try again.

My 5 spd pops out of first gear periodically. Not all the time. Seems to go in runs and the process is as follows:

1. Sit at stop light car in 1st gear
2. Engage clutch, car rolls a few feet, pops out of gear
3. Wait for RPM to go back to idle (if not, will grind)
4. Engage clutch, car rolls... sometimes is ok, sometimes will pop again

Steps 2 through 4 can happen only 1 time, or can happen 3 or 4 times. This can be very annoying and dangerous at stop lights. I don't want to get rear ended.

New clutch and linkages. Stock shifter parts.

Everything I'm hearing is to dump the tranny. I'm wondering if this could be something as stupid as a fluid change (haven't changed in forever), or if there is a repair that can be done?

I would appreciate any thoughts, comments, or advice on this.

Thanks much,
Rod

[bimmerd00d]

Well, i hate to be the bearer of bad news but this could mean a few things. Bad clutch (possibly bad slave cylinder), worn synchros, shifter fork might be going bad, linkage twisted or bent. If you hold the shifter in first will it pop out with more force than you can hold?

EDIT: didn't see the new clutch/linkages part. I would lean towards a bad slave cylinder, or bad shifter fork or synchros. Which means, you can rebuild it, or find a refurb'd or new tranny. I spent about $1050 on a reburb'd tranny for my '93 525i when this identical thing happened. At some point, your tranny will get stuck in a gear or neutral and you wont be able to shift in or out of any gear.

[632 Regal]

yep bad syncros and gear forks inside the trans can be worn.

[talltorontoguy]

Thanks for the info (although bad news for me).

Which is best bang for buck... a used tranny or do a rebuild?

If I can get a rebuilt tranny it might have the same issues.

Is there a rebuild procedure / experience posted anywhere?

Rod

[Warren N.CA]

RedLine MTL is my favorite. If your shifter has never been overhauled, it probably has numerous worn out parts. They should be replaced, which might clear the problem.

Hi all, I posted about this in the spring and didn't get much of a response so thought I would try again.

My 5 spd pops out of first gear periodically. Not all the time. Seems to go in runs and the process is as follows:

1. Sit at stop light car in 1st gear
2. Engage clutch, car rolls a few feet, pops out of gear
3. Wait for RPM to go back to idle (if not, will grind)
4. Engage clutch, car rolls... sometimes is ok, sometimes will pop again

Steps 2 through 4 can happen only 1 time, or can happen 3 or 4 times. This can be very annoying and dangerous at stop lights. I don't want to get rear ended.

New clutch and linkages. Stock shifter parts.

Everything I'm hearing is to dump the tranny. I'm wondering if this could be something as stupid as a fluid change (haven't changed in forever), or if there is a repair that can be done?

I would appreciate any thoughts, comments, or advice on this.

Thanks much,
Rod

[bimmerd00d]

Thanks for the info (although bad news for me).

Which is best bang for buck... a used tranny or do a rebuild?

If I can get a rebuilt tranny it might have the same issues.

Is there a rebuild procedure / experience posted anywhere?

Rod

rebulit/refurb'd units will have the common wear parts updated.

[Martin in Bellevue]

Hasn't happened since. MTL went in late last year.

[talltorontoguy]

Thanks for the reply guys.

I should have stated that a used tranny might have the same issues, vs a rebuilt one which would obviously have been overhauled.

Still looking for a rebuild procedure.

Rod

[Jeff N.]

Chech yer motor and tranny mounts. Swap fluids as Martin B - geeenuius - suggests. Rebuild your linkage with new parts. Theeeeen, if it still sucks, put in a different tranny. But not before.

BTW, 2nd gear syncro tends to go first - before the 1st gear synco. If 2nds' fine and first isn't, I guess you can fix it with one of the above.

Jeff

Thanks for the reply guys.

I should have stated that a used tranny might have the same issues, vs a rebuilt one which would obviously have been overhauled.

Still looking for a rebuild procedure.

Rod

[talltorontoguy]

Thanks for that tidbit of information. I'll try those suggestions first.

In the event they don't work... anyone have a line on a used 5 speed?

Rod