Hi,
I'll take a stab at this.
Your transmission has one of the following problems:
1. The main-shaft end float is excessive.
2. The top hat bushing is in the process of destroying itself.
3. The "thrust washers" for the layshaft are worn excessively.
Popping out of gear is more related to the gears being able to move
around on the shafts than it is to wear on the gears or the gear "dog teeth".
Note that 1 and 2 above can be related. The top-hat bushing can break at
the top-hat which then allows the bushing to grind itself to pieces. The
end float for 2nd and 3rd becomes greater and greater until other big
problems occur.
Get that sucker out of the car and have a look in there.
Note: from the past:
Color of TRansmission oil:
Golden - normal - possibly new. Good
Golden/metalflake - not normal - oh oh - synchros or thrust washers. Bad.
Brown - possibly normal - time for a change.
Grey - not good - this is bearings or the shafts wearing - expensive. BAD.
Note: I drove my TR6 with it popping out of 3rd for 5 years without any
major problems except having to hold the gear selector in place when
driving down hills in 3rd. The most excessive wear in that particular
'box was the thrust washers for the layshaft.
The "notchyness" may be something else... my car currently does not like
shifting into 2nd and 4th. I think I broke a thrust washer in there. I'll
find out this week.
bye,
rml
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