Why has my Ford Transit gear change suddenly become stiff and started clicking?

A gear change that suddenly becomes stiff, with clicking from the gear lever area, is a familiar problem on cable-operated Transits, including the MK6 FWD and all MK7 models. The good news is that the cables themselves are almost never the cause. The selector turret on top of the gearbox seizes: its bearing corrodes, the cage breaks up and loose balls restrict movement. The clicking at the lever occurs because the cabin mechanism is working against much greater resistance. Repair is inexpensive, as a selector repair kit costs a fraction of new cables. Owners with mileages around 250,000 km confirm that the original cables can outlast the van.

What if the gear lever is loose and the van jumps out of gear?

The opposite symptoms, including a rubbery lever, difficulty selecting the correct gear and gears jumping out under acceleration or engine braking, point to a stretched cable, broken plastic clips at the cable ends or play in the lever mechanism. There is also a less obvious cause confirmed by workshop experience: cracking in the floor around the gear-change mechanism mounting, which can make the lever feel equally vague, so inspect this area as well. After replacing or adjusting the cables, lock the mechanism in neutral with an M10x30 bolt in the hole beneath the lever before attaching the cable ends.