I've posts about a few other people with '04s that have this issue. I have 41k miles. My warranty is up March 28th, so I have a few weeks left to get this fixed.
The problem is that it is not always reproducible, especially not when I have the shop techs look at it. It only grinds sometimes, and usually only in the high rpms.
Suggestions?

 

take a tech with you so you can reduplicate the problem, or you can do what i did when my warrenty was about up i beat the **** outa the gear that was grinding until it did it everytime.. not the most settle or proper way to go at it but the dealer is just gona f*ck around till your warranty is up then too bad so sad for you...

 

I would love to take a tech along, but the problem is that it doesn't always do it. So far I have not found a pattern or a way to reliably reproduce the problem

 

well id start w/ checking your tranny fluid making sure its full, put redline tranny fluid in it, last beat fourth gear till it grinds every time. make it grind!

 

We have same issue here.
https://www.rx8club.com/series-i-tech-garage-22/2nd-gear-grinds-when-downshifting-166538/

 

Car's at the local mazda dealer/shop now. They're scaring me saying mazda might not cover it, but I know they can't make promises about that kind of thing. My transmission's fate is in MNAO's hands now......

 

it is under the 5 yr 60k mile powertrain warranty, why would they not cover it?

it is not like this has not happened before.

beers

 

Phew, ok MNAO has authorized the repair! New 3rd & 4th synchro and 3rd & 4th gear and shift forks. Load off my mind....
Parts arrive tuesday, so until then: