Join Date: Jul 2008
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A few reasons the shifter pops out of gear:
1) Detent ball or spring for that gate position is worn, so selector (and fork) are not properly held in place.
2) Synchromesh ring (also known as a 'synchro' or blocking ring) worn, not aligning, or keeping synchro gear from locking on to the gear.
3) Worn or missing shift dogs under synchro gear.
I had a Borg-Warner T-5 do this in 3rd gear every so often, I'd have to hold it forward until it was time to shift, then shift. Eventually, it locked itself into gear. One of the shift dogs was loose, and one got spat out and locked the synchro gear on the trans gear, effectively locking me into 3rd gear! That was an entertaining ride home.
Long story short, sounds like a good time for a rebuild, or at least some recon under the cover.
1995 F250 XLT 7.3T (on donor '97 engine with 180xxx miles) 4x4 - LuK SMF, Diamond Eye 3" downpipe to 5"straight-pipe exhaust. ZF5 manual trans, Curt hide-away gooseneck hitch, Super Duty suspension conversion.
1997 F250 XLT 7.3T - 2wd E4OD, alloy wheels w/ bald tires, gooseneck hitch, pretty much bone stock. Soon to become a trailer, spare tires, spare parts, and scrap.