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I hope I've explained it clearly enough, but if I haven't please tell me.
And if you aren't adjusting the ratios, then I have no idea what the problem is.
As far as my problem is concerned, I have tried starting a new game (not from a save game), with no gear tampering, on Novice mode, all options off. I still occasionally get a 5th gear max out. Usually the only way to clear it, is to start a new session. Though bizarrely I have seen 6th and 7th gear become available again with no action. Utterly bizarre (and not to mention potentially ruining the game).
I do remember from another topic in this forum that someone mentioned about the right stick for accelerate/brake and don't mix the two up cos the PS2 then gets confused.
I had done this in the 1st lap for a good getaway and then found after being about 3 seconds in the lead that'd I'd change back to using x and square as normal....opps within half a lap I was backof the grid and no hope of winning!
Tried a full stop and then accelerate with x no change, tried a lap on rubbish gears thinking that the PS2 would sort itself out but nope....ok I'll switch off and since then been ok.
Take heed of the advice and try not to use both in the same race, it'll only backfire in the end!