I've got a 2007 1.8 Zetec that I took into the garage as it was jumping out of 2nd gear when going down the box and crunching when going up. Anyhow, garage says the gearbox is generally a bit worn and the clutch is on the way out (car has done 85k miles). £1k later I have a recon'd box and new clutch with new cylinders, refaced flywheel etc but it still jumps out of 2nd gear ! The garage have have the car back at the moment and have replaced everything to do with 2nd gear (selector forks etc) in the recon box but I have a feeling it is still going to be doing it when I pick it up tomorrow. I have used the garage for years and take them at their word that they have replaced the box, so assuming it still jumps out of 2nd tomorrow what else could it be ? I'm thinking an engine / gearbox mount somewhere maybe ? Not sure what else could cause it ?

 

Bent selector forks.

 

That was what I was thinking, but what are the chances of a reconditioned gearbox having bent selector forks on 2nd gear the same as the one that was taken out ? I really don't want to think the worst of the garage but if the fault has gone when I pick it up later I will have to ask questions ....