Intermittent stiff gearbox - SOLVED
2009 Ford KA 1.2 RU08 (Fiat 500)

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Ford Ka RU08
Driver
1 points

Problem added: Mar 4, 2021 (1 month ago)
Increasing difficulty in selecting into the 5th / reverse plane, and gear lever generally stiff, not springing back into the neutral position from this plane.
Found to be that the shift inner cable-rod for side-to-side movement is exposed at the gearbox end when in the 1st/2nd plane. This (and lack of use during COVID) meant that surface rust on the cable-rod restricted movement to & from the 5th / reverse plane as it could not smoothly slide back into the cable sheath.
To fix, i removed the battery and battery tray to access the linkage visible on top of the gearbox (forward-backward gearlever movement is the cable below-rear of the 'box), selected 1st gear to maximise exposure of the cable-rod and lightly abraided the rust off followed by application of grease and several movements into / out of 5th gear to free it up and attempt to grease the cable sheath inner.
To prevent reoccurrence, i now leave the car in 5th / reverse gear when parked so that the cable-rod is not exposed.
Hope this helps someone.

Car details
Car: Ford KA
Variant: 1.2 RU08 (Fiat 500)
Model Year: 2009
Category: Gearbox & Clutch
Replies and Fixes
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whittingehame
Legend
18,349 points

Mar 4, 2021 (1 month ago)
Grease on cable is not a good idea as it dries up with heat , attracts dirt and eventually causes problems . You could use Copper Grease for the heat but even that attracts dirt and wont help
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Ford Ka RU08
Driver
1 points

Mar 4, 2021 (1 month ago)
Thanks for the added advice - i'll clean the excess grease off and look for a rubber gaiter that will cover & protect longer term. Hoping that this alongside parking in the 'correct' gear to minimise exposure of both of the cable inners when car is not in use will prevent further issues.
Avatar
whittingehame
Legend
18,349 points

Mar 4, 2021 (1 month ago)
Another hazard motorists face apart from the common low battery problems due to lack of use from Covid and restrictions .
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