Hi jim.............

Ok the clutch actuator unit also incorperates the transmission control module inside it now these modules are programmed to the vehicle so if you get a new one of these then it will have to be reprogrammed to the vehicle to work and the transmission parameters will need to be relearned to it which will need to be done at your local ford dealer.

If they are just repaing it and sending you it back then you will need to have the clutch touch point relearned and the clutch bleed done and also the shift motors will have to be relearned so the control module knows what gear the vehicle is in and again this needs to be done by your local dealer as the diagnostic machine is required.

Normally what happens is when the ignition is switched on the tcm unit looks to see what gear it is in now if it is in a gear then it will automactially put the vehicle into neutral so the vehicle can be started how ever if the tcm can not determine what gear it is in or cannot move it out of gear then the vehicle will not start, but it should when plugged back in put the vehicle back into neutral.

I have to say that i have never know one of these units fail before and from what you have described it sounds as thou your shift motors have stuck causing the vehicle not to come out of gear. I would just pull the cover of the front of the motors and see if you can put it in neutral by hand were it connects to the gearbox if you cannot then your motors are stuck, also just have a little look at the wiring were it comes down from both motors as it use to get water into it and cause it to become corroded so the motors didn't work.

Hope this is ok for you if you require any further help then please ask as in always glad to help

Kind Regards

Neil