Take it back, this time they will replace the whole transmission.

 

Greetings,

The TSB is 08-9-6, you can google it or search this forum on the top right of the blue border and you will find it.

The ford dealer should replace your synchros and the problem is supposed to be fixed.

Other members have switched to GM Synromesh fluid in the trans and Royal purple fluid seems to be a popular switch.

I personally had problems with 1st to 2nd and equipped an aftermarket shifter, poly motor mounts and the CHE K member brace with torque limiters and I would suggest those products, in that order to help with shifting. Btw, I changed to Amsoil ATF at the same time and the car shifts like a dream now.

I was having a shifting problem at HIGH RPM's however, and not a cold start related grind. The cold start related grind seems to be more indicative of the synchro problem and should be corrected by the dealer, if you're still under warranty then just take it in, if not, check out American Powertrain, they're in NC and seem to have reasonable pricing for some quality transmission work. One of their employees or owners is a member of this forum, but I haven't seem him post in a long time.

Hope this information helps.