u/piano4tay

Hi all,
I’m posting here because my 2008 Mazda BT-50 is mechanically almost identical to the PJ/PK Ford Ranger, and I’m hoping someone has come across this fault.
Vehicle:
2008 Mazda BT-50 (UN)
2.5 diesel
5-speed manual
Part-time 4WD
Only 40,000 miles from new
The fault
Only 5th gear is affected.
At about 50–60 mph, while maintaining speed or under light acceleration, the gear lever physically jumps back into neutral.
There is no crunching, grinding or graunching.
It doesn’t jump out immediately after selecting 5th—it can stay in gear for a while and then suddenly pop out.
1st to 4th and reverse are completely normal.
History
Exactly the same thing happened about 3–4 years ago.
At that time I had the manual gearbox oil changed, and the problem appeared to disappear completely for several years.
The fault has now returned. I’ve just had the gearbox oil changed again with the correct oil, but this time it has made no difference.
What I’m trying to establish
Before I authorise the gearbox to be removed, I’d really like to know whether anyone has had this exact fault on a PJ/PK Ranger or BT-50.
If you did:
What turned out to be the actual cause?
Was it repaired, or did the gearbox have to be replaced?
Was the fault confined to the 5th-gear assembly?
Did anyone find something relatively simple, such as excessive end float or a selector problem?
I’m particularly interested in replies from people who have actually repaired one of these gearboxes, or gearbox rebuilders who know this transmission.
Many thanks.

Hi everyone,
I’m hoping someone has seen this before.
I have a 2008 Mazda BT-50 2.5 diesel, 5-speed manual, part-time 4WD. It has covered only 40,000 miles from new.
The fault is very specific:
Only 5th gear is affected.
At around 50–60 mph, while maintaining speed or under light load, the gear lever is physically pushed back into neutral.
There is no crunching, grinding or graunching when it happens.
All the other gears are perfect.
Interestingly, exactly the same thing happened about 3–4 years ago. At that time I had the gearbox oil changed, and the problem appeared to disappear completely for several years.
The fault has now returned. I’ve just had the gearbox oil changed again, but this time it has made no difference.
Before I authorise the gearbox to be removed, I’m trying to establish whether this is a known fault on the BT-50 / equivalent Ford Ranger gearbox.
Has anyone experienced these exact symptoms?
If so, what was the actual cause?
5th gear retaining nut?
Selector fork?
Synchroniser hub/sleeve?
Worn engagement dogs?
Something else?
I’d really appreciate hearing from anyone who’s actually repaired one, or from anyone with experience of these gearboxes.
If anyone has workshop manual pages or technical service bulletins relating to this fault, I’d be especially
grateful

Thanks very much.

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Very grateful for any advice before I tackle Samsung’s helpline….