Hey Guys. I have some questions regarding the getrag manual 5 speed transmission. I think the number on mine is 717.411


I just put this in my car after a quick reseal/regasket. Also needed to pick up a new spring for the 5th/reverse shift fork. I have never run this transmission before so I'm not sure if this issue is something I caused during reassembly or if it was an issue the whole time.

Whats happening is that it is coming out of 4th gear while driving. When I'm making the shift from 3rd to 4th everything goes normal/smoothly and then I'm able to apply throttle once the clutch is engaged and drive like any other car. I can cruise in 4th gear like this no problem but as soon as I let off the gas pedal it pops out. I can keep my hand on the shifter to hold it in place but I can feel something trying to fight my hand and disengage it.

I did some further testing with this gear and noticed that if I put it in 4th while going slow (around 20 to 30MPH) and keep the RPMs under 1200 it doesn't have this issue at all. Im able to let off and apply the gas pedal as much as I want and it wont pop out. its almost like letting off the gas pedal at high RPMs is jerking the transmission so much it pops it out of gear.


Every other gear on the transmission functions as it should. I did have to make custom shift linkage for my application but I am very certain it is fully engaging because the lever on the transmission cannot go any further forward while the shifter (if linkage is disconnected) is able to push the lever even further (not that it is possible when linkage is hook up as lever on transmission stops). So it seems that I have the proper movement with my linkage, I would also think if that linkage rod was too short or too long that it would also effect 3rd gear but that is functioning perfectly.



So on to my questions. Has anyone else experienced this before even if it was on a different gear, and if so what did the issue end up being?


Could this be an issue with the custom linkage I made? even though 3rd gear works fine. (3rd and 4th use the same linkage rod)


If I do have to drop the tranny again (it seems like that is the next logical step) what should I be looking for when I disassemble it? all I can think to check would be the shift fork and detent mechanism for it.



Thank you so much in advance to anyone with some insight on this.

I can only speak generically. It coming out of gear implies that it did not go completely into gear completely. which can be a linkage issue or I had a vehicle that had a worn sifter fork (worn on one face) that was not pushing the gear in far enough.

I am looking in a W123 manual at a 5 speed and it has specific dimensions from the front of the transmission for each of the 3 levers. There is no numbers just listed as A, B, and C.

Hopefully someone can give you a more specific answer.

If you keep your hand on the shift lever will that prevent the gear from disengaging?

I think you could put it into 4 gear and carefully remove the sifter lever cover and see what position the gear is actually in and also inspect the teeth on the Gear to see if they are worn (what other type of wear could cause the symptom).

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84 300D, 82 Volvo 244Gl Diesel

Thanks for the insight. I think the 5 speed transmission you are talking about is the older style as mine does not have a side cover near the shifter arms. I have a getrag 717.411, full aluminum body. I think the ones with side covers are the older style then in around 1980 getrag made the 717.400 for the OM616 and OM617. The 717.400 very similar to the one I'm working on I think. either way Im sure there are similar specifications for my transmission. Ill have to check on that.


It will stay in gear if I keep my hand on the shifter.

I made the shift linkage for 3rd and 4th adjustable yesterday (about 40mm range of adjustment). went in both directions with no effect other than binding up the shifter assembly. I can confirm the shift arm on the transmission is fully engaged, or it is fully bottomed out at least unless something internal is stopping it and it should be going forward more. Based on the other shift arm movements it is fully engaged.

I think you might be on to something with one side of the shift forks worn more than the other. Ill have to find specs for those

Kb:
Generically speaking (also), there are a number of areas that could contribute to the 4th gear pop-out. Worn pilot bearing, excess end play in the input shaft bearing (wear and/or shimming), wear in the input shaft-to-main shaft roller bearing, worn synchronizer dog teeth on the input shaft, worn synchronizer sliding ring, worn or missing detent balls & springs in synchronizer, excess end play in main shaft, and the above-mentioned worn shift fork.