2nd gear pops sometimes???

Mustang5L5 said:

Usually its a sign that the dog teeth on the 2nd gear and 1-2 slider have seen better days. You'll need to open to inspect, but you might need to purchase a new 2nd gear and 1-2 slider. eBay actually has decent prices on these gears from aftermarket vendors. Purchase a new blocker ring for 2nd gear and you could do the entire job for under 100 bucks if you can take a trans apart.

But while you are there, might as well purchase a complete rebuild kit and replace all the blockers and bearings.

FYI, all 85+mustang t-5 are world class. To identify what model you have, you either need the tag on the trans bell housing tom decode, or you open the trans up and read the 3-digit code off the counter gear to determine the gear set

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MFE92 said:

2nd gear syncro has seen better days. If you can remove and reinstall the trans, you're proficient enough to rebuild it, IF you have a couple of extra tools and some good instruction. You'll want access to a press, you'll need some inside and outside snap ring pliers, a specific torx bit, and a dial indicator. There are instruction videos from Hanlon Racing and others, and there's a good writeup at pomoforacing.com

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