1997 f150 xlt 5 spd, 2nd gear kicks out when you let off the clutch and start to grind. Is this snycro's? A partial rebuild by previous owner 2000 miles ago.

Is power shifting a reason for this problem to start all of a sudden and is power shifting harder on the tranny?

 

Most likely it is internal so here are a few things it maybe.
1.synchronizer sleeves have free movement on their hubs.
2.synchronizer blocking rings have damage on the index slots
3. countershaft cluster gear has excessive play
4.shift forks could be worn or loose on the shift rails
5. fork pads worn
6. synchronizer sliding sleeve and gear clutch teeth worn or damaged

Power shifting could definitly be a reason for internal damage like that. So to answer the other ?........No it's not good. Have you drained the fluid and checked the bolt to see if there was any metal sticking to it ?

 

If by power shifting, you mean shifting without the clutch - yes, this can be tough on the synchro's if the gears are jammed with a rotational difference between the engine and drive axle (either an accel or decel condition). The tranny has to eat the difference, rather than the clutch lining.

Your 2nd gear problem also sounds like a synchro problem, temporarily can work around by physically holding the shifter HARD into that gear.

Why did the tranny need a rebuild? Sounds questionable right there.

 

thanks, just out for another tour with it... reverse seems jambed and doesnt even budge the truck. i have no other gears but second even in neutral its still in second..

 

now that its stuck in 2nd you should pull the shifter out and try shifting the trans with a long screw driver or metal rod and see if its just your shifter or internal

also to what you mean by power shifting my guess is shifting trans super fast with clutch in and gas still floored if thats what you mean it should not cause this problem as long as your using the clutch but it will wear your sycros faster than slow normal shifting as well as wearing the clutch faster

somthing sounds fishy if the trans was rebiult 2k ago the rebiulder probobly set somthing up wrong

 

by power shifting i mean no clutch.. And i had to take it in to the tranny shop still under warrenty sounds like the slip yolk boke again