I had the same problem with my t-5 and it wasn't the synchro's it was the shift fork. It had worn to a point that it wouldn't push second gear into place all the way so it would grind or even pop out while driving. I would recommend going to a good tranny shop and have them take a look before spending a heap of money on a new tranny. It cost me $400 bucks and haven't had a problem since. Good Luck!!
thad
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90 LX 5.0 ,bored 302, MSD 6AL, Twisted Wedge TrickFlo HDs, World class T5, BBK fender cold air induct., 70mm TB,Edelbrock performer Intake, aluminum Drve shaft, 3.55 Gears, Long Tube Headers to Flowmasters.
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