I have a 1994 F-150 Extended Cab with 4-wheel drive, a 5.0-liter SFI V8 engine and an automatic transmission.
I'm having a problem with the transmission. It was rebuilt under warranty about 16 months ago at a Ford dealership because of a shifting problem from 1st to 2nd gear. Now the same problem came back.
Have there been any common problems with this transmission, or were there any recalls for this problem?
There aren't any recalls that apply to a '94 F-series transmission, but Technical Service Bulletins are another story. Typically recalls are only issued pertaining to emissions or safety related problems. Technical service bulletins (TSB) are published whenever a failure occurs enough times to warrant a better fix than what's published in the service manual. Very often the repairs involve modified parts which are more durable than the original factory stuff.
An automatic transmission is a complex device with a lot of parts. Therefore, there are usually quite a few service bulletins in that category. I did a service bulletin search on your truck with the Alldata information system, and like I said, there are quite a few in the transmission section. Your F-150 could be using one of two different transmissions: the E40D or the 4R70W (AODE-W) unit which are both four-speed automatics.
Ford TSB # 97-11-11 involves the 4R70W(AODE-W) transmission and pertains to a 1-2 shift problem due to premature wear on the accumulator seals. This wear is caused by an excessive piston side-load which scuffs the piston bore. The modification includes a stamped steel accumulator piston as a replacement to the cast aluminum factory part, along with an updated return spring. Your transmission may have been repaired without these modifications, which could cause a repeat failure in a short period of time.
This is one possible cause to the problem. The best way to go is with a factory rebuilt unit which has all the appropriate modifications completed before given the official stamp of approval. Explain your situation at the service department. They should help you out if it is indeed a repeat failure.