Small update, but kind of a cool one. My truck (and most Ford products made in America, I think) originally came with a sticker on the windshield that said where it was built and that it was built by UAW workers. The sticker was long gone by the time I got my truck, but I kinda would've liked to have had it, just because it's a big "Made in America" sticker. My truck was built at the Kansas City Truck Plant in Claycomo, MO where F150s are still built today. So I wrote a short letter to the local UAW that represents the plant, and explained that I spent a lot of time fixing up this truck and if they'd be kind enough to send me a replacement sticker, I'd appreciate it. So today in the mail I got a letter back, and they included two of those stickers along with a couple other ones.
So it's something small but a nice finishing touch.
I've been dailying the truck for a while with no real issues to note, it was pretty reliable... Until last week. I pulled into my driveway in second gear with my foot on the clutch and coasted downhill into my parking spot. When I went to put it in first to park it, it went into neutral, and now won't go into any gear, and the shifter is all over the place.
So I spent the morning pulling out the transmission. I pulled it out with the transfer case still attached, which was probably the hard way, but hindsight is 20/20.
Anyway I'm gonna pull the top cover off tomorrow and see if it is maybe a simple fix, but I'm counting on having to replace the whole trans. This would be an opportune time to swap to a much stronger and better geared ZF5 so I've got my eyes peeled for one.
The clutch looks to be at about 50% life, but I'm gonna go ahead and put a clutch kit and a new hydraulic throw out bearing in while the trans is out. Anyways, I'll update as I go along.
Glad it's just a mechanical issue. Was afraid you were going to say someone got out in front of you and caused a wreck and it was totaled.
I doubt there is a catastrophic failure in the transmission based on your description. Either a problem with the shifter or a broken shift fork or internal shift linkage. I'm not familiar with that transmission so its hard for me to say. If you haven't opened one up, don't be afraid to do so. They aren't that hard to work on. I'm sure the procedure is available online. Just takes attention to detail. Nothing wrong with upgrading to a better gearbox while you have it out though.
I don't actually think it's a catastrophic failure either, these transmissions are known for breaking shift forks, which is what I think probably happened. Still I'm not sure if I want to put any money into this trans, especially when a ZF5 is pretty much a direct swap.
I did pull the top cover off today and the problem is in the top cover. I don't know enough about what I'm looking at to find pinpoint the issue, but the binding is occurring in the top plate and not the transmission itself. The synchros looked a little worn to me and here always has been a grind from 1-2 and sometimes from 2-3. So I'm gonna take it to a transmission shop tomorrow and let them inspect everything quote me a price to replace the synchros and fix whatever the issue is in the top cover. Then I'll decide what I want to do from there.