tremec 3650 right? there is a TSB out on them, but you still have to pay $900-$1200 for a dealer to fix it. Basically the synchros go out in 1st and 2nd gear. Maybe somebody else can chime in, but I'm thinking you should take it to a reputable tranny shop and have them check it out. You can find a brand new TKO 500 for around $1,600.
Mine grinds going into 1st from any speed except 0mph. I just deal with it and stay in second or come to a complete stop. Most folks with 3650 problems experience exactly what you are... jumping out of and grinding into 2nd. Hell, there's about a 3,000 post sticky on Stangnet about it. Grab a case or two and read it.
I've heard that Ford Dealers charge $900 for the kit and $200-$300 for the labor. There's a guy on Modular Depot and Stangnet... his name is Randy Stinchcomb or something and he works and a big dealer in Maryland. He has his own section on Modular Depot called "Ford Parts".
http://forums.modulardepot.com/ford-factory-parts/
Anyway, you can order the synchro TSB kit straight from him for about $650.
Before you panic, how long has it been since you changed the fluid? If never, most people suggest GM synchromesh and exactly 3.2 quarts no matter what the manual says. I'm going to try this on mine soon (just another good reason to buy a shifter!)
If mine breaks, I'm going to take it to Hodge Transmission in Connellsville.
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