Re: More problems with 6 speed, 5 gear popping out
5th gear coming out is a pilot brg thing. In this "gear" there is no gear involved, just the coupling between the input shaft and tailshaft. When the input shaft is crooked (supported on the front by the pilot brg) it walks the sleeve out of the synchro and spits out the fork. In no uncertain terms, it is warrantable IF you bought the pilot from the gearbox vendor. If they were separately sourced, you can see the gearbox vendor's point - why should they warrant a $2k part for the sake of someone else's $10 part failure?
Of course, the other thing (you will hope) is that the pilot is fine, and the last failure of the gearbox was not properly repaired. Was it a genuine ZF reman or done by another shop? I hate to cast doubts, but a fair number of "reman" trannies are simply junkyard parts that are carefully washed and shipped. Of course, that is NOT the case for ZF!
2000 F450 Lariat 4x4 tractor, rebuild at 200k in '12, Air Dog, Reg Mod, HX & HP all in hard SS lines, bypass filter, Banks Power Elbow w/3.5 dp, no intake heat, CCV mod, AIS (w/extra hole), some big Alliant single shots, GP indicator LED, custom 4" exhaust, 4" USG exhaust brake, custom alum. rear diff cover extension (dipstick & temp), Detroit locker, ESPAR D5 aux. heat, custom alum tow deck and fuel tanks, Bushwacker 1 1/2" flares, 9k winch, gin poles, JWSpeaker 8900 LED headlamps in XL grille, Lightforce 240GT (still Halogen, but VERY bright), Hella Micro DE HID fogs, KW = vision plus (Isspro) instruments, more to come & lots of other diesels