second gear pops out when coasting and slowing what is it and whats involved and she crunches when you go 1st to 2nd and 3rd to 2nd......

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people say keep ya friends close and you enemies closer BAH I say keep your friends close and your enemies at maximum effective range.

synchomesh is worn, pretty common in second gear

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real men race downhill - keiichi tsuchiya

lots of mini gearboxes wear out the synchro on 2nd, why only second????

my old one was a real (want to swear but shouldnt...) when it came to the crunch, if its serious you may want to look at getting it reco'd

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78 Leyland Mini - Prince

how involved and........expensive is that??????

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people say keep ya friends close and you enemies closer BAH I say keep your friends close and your enemies at maximum effective range.

mixed bag really, its like lifting up vinyl flooring, you could discover alot worse stuff that needs fixing, PITA is you've got to seperate the box from the block, and while your there....etc etc its a good time to do stuff right.
sorry cant help you on price, everybody has diff rates. luckily i have a friend who does it for around $200, plus parts and guiness.

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real men race downhill - keiichi tsuchiya

Like the K said, bit of a Pandora's Box (bad pun)
The synchro rings are about $30-$40 each - need 4, plus the layshaft & bearings will inevitably be worn. Then you need to check 1st motion, spiggot & main centre bearings so it soon adds up. Obviously you can reduce labour costs by removing/repalcing it yourself but even then your'e probably up for about $700 for a decent recon.

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1967 Cooper S - new front bearings to do.
1965 Cooper S shell - Slow progress. No time or money!
1966 Deluxe- next rustoration!
Mk 2 & XJ6 Jags. Less said the better.

Or you can put up with it till it's really bad , I drove one like that for over 20,000 k's , just go slowly on the downshift and when it get's worse double clutch it into 2nd . It'll teach you how to be kinder to the gearbox as well , mini gearboxes don't like snap changes into 2nd .

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I'd agree - you don't have to rush into fixing the box. Yes, what's been described is a fault and needs fixing, and it will get worse but, if you can live with it you'll have the opportunity to learn a bit more about your car, and how to treat it well. Treated kindly, you can keep going for a fair bit.
And the reasons why second's synchro is the one that generally goes first are that second gets used a lot - probably more than any other gear - and there is a decent speed difference that the synchro needs to overcome. In other words, the higher the ratio, the harder the synchro has to work. Fourth is generally a 1:1 ratio, so it's not hard for the synchro to speed up the gears, where 2nd is usually more like 1:1.8 (roughly), so the synchro's got to work about 1.8 times as hard, because it's got to make the input shaft spin 1.8 times faster for second than for fourth at a given speed.

Keep the oil changes coming, regularly clean the magnetic particle attraction rod on the sump plug and maybe think about adding rare-earth magnets to your oil filter to (hopefullly) extend the life of the box before maintenance

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"Show me the Mini!"

My old mini's g/box had the exact same prob... there was no chance in hell of changing down from 3rd to 2nd, and If you tryed to accelerate in 2nd.. POP!! When you know how to double clutch, its soo much more fun... being able to downshift into 2nd around the corners instead of put-ing around in 3rd he he. Not many people could drive my car, 'cept me and my dad...

rare-earth magnets..................

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people say keep ya friends close and you enemies closer BAH I say keep your friends close and your enemies at maximum effective range.

Yeah...rare-earth magnets, powerful, focussed magnets that pull out all the magnetic particles shed by the complaining synchro rings....clean oil IS the best mechanic

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"Show me the Mini!"

where do i get them from??????????

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people say keep ya friends close and you enemies closer BAH I say keep your friends close and your enemies at maximum effective range.

Gafmo??? or search on magnets.....and attach them to your oil filter

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"Show me the Mini!"

Know of anyone with a dead hard drive in their puta? These magnets can be ripped out of one of them and then tapped to oil filter.

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If in doubt ask