I would like to express my Thanks to Deysha and Jason at Ford Customer Service. My case for my 1-2 shift issue on my 2010 was turned over to Jason who kept me informed while the Shelby was at Texas Motors Ford being repaired. Parts replaced are as follows:
AR3Z 7124 BA Synchro Assy
8R3Z 7230 A Fork 1st and 2nd
AR3Z 7102 2nd Gear
AR3Z 7107 A Ring Synchro
7R3Z 7A082 Kit Trans Control
7R3Z 7107 A Synchro Blocking Ring
1R3Z 7L082 AA Gear Change Fork Insert
XT 11 QDC Fluid
The people and Service at Texas Motors Ford is outstanding. Service Manager Mike Bright, Service Writer Santos Pena and Service Tech par excellence, Win Horn, were great folks. I can't say enough. I spent a good hour talking to Win on the history of the 6060, the T-56 and what his thoughts are on what is going on with this transmission. All I can say is the car shifts better than the very first day and no grind. My only concern is that replacement parts are no different than what was taken out so at some point down the road, this issue may come back. I did a lot of back and forth with the Tremec Tech Support and Ford Customer Service. According to Tremec, they have made some changes to the internals, mainly 2nd gear and a change to a carbon fiber blocking ring instead of the sintered bronze ring. Not exactly sure what change/s/ were made to second gear. Tremec stated that when ordering new parts I should have received the updated parts however that was not the case. The blocking ring installed was of the sintered bronze design and second gear was the same as the original. We will see how this plays out since my original grind issue started at about 3K and ultimately got to the point of grinding at anytime over 3500 RPM at 8.7K. Win stated that in his experience, grinding seemed to occur at RPM's above 3500 in most cases he had seen.
One thing to note, Liberty Gear offers a carbon fiber blocking ring for the 6060, an upgraded 2nd gear, and also offers bronze fork pads for the shift forks instead of the plastic OE. If I ever have to go into the trans again, these parts will be installed.
My only concern about this whole matter was that I have yet to see any explanation on what is the root cause for the issue. I found it odd that Tremec has upgraded several components yet FORD installs original design parts. Not a big thing, just found it odd. Dealer has no say as to what they can install. They must install what is authorized under the warranty which is understandable.
One other item worth noting is that during the repair cycle, Ford Tech line was contacted regarding use of the Dual Clutch Transmission fluid which they agreed to go ahead and try. This fluid is a full synthetic, very light in viscosity, almost as thin as Mercon V and IMO feels slicker than Merc V. Win and I had a lengthy discussion on trans fluid and in his experience what he has seen over the years regarding ATF in manual tranny's. I am noting this in the event any of you would care to venture into changing out the current fluid for this type and see what happens. This is not an opportunity for everyone to jump on board and go off the deep end about using a non-spec'd fluid and how could I do such a thing. I trust the trans guy and I trust Ford Tech and after 40 some odd years of working on cars myself, I trust myself to agree this is worth trying.
In closing, not sure what makes this tranny perform so well now. I can't say if it is the shifter (definitely better than OEM that's for sure) the fluid, new parts or the time, care, and know how of the trans tech or it's a combination of all. It all works!
Again, hats off to FORD Customer Service - Jason and Deysha and Texas Motors Ford, Mike Bright, Santos Pena, and Win Horn.
Sorry for the lengthy post.