2000 240 EFI Challenger - Stiff Shift Cable

[nenikol23]

The shift lever on my 240 Challenger is EXTREMELY stiff. I just installed a new shift cable 2 weeks ago. The bucket in the back is not hard to move by hand. I Also tested the cable before installing, like butter. But took it out yesterday and had a lot of trouble. Once in forward, it was impossible to put it back to Neutral. Had to jump in the water, move the bucket manually so we can start again and go. I won't even talk about docking which was a nightmare without reverse. What do you guys think should I check/do to fix this hopefully simple issue....T

 

[Tim75]

The shift lever on my 240 Challenger is EXTREMELY stiff. I just installed a new shift cable 2 weeks ago. The bucket in the back is not hard to move by hand. I Also tested the cable before installing, like butter. But took it out yesterday and had a lot of trouble. Once in forward, it was impossible to put it back to Neutral. Had to jump in the water, move the bucket manually so we can start again and go. I won't even talk about docking which was a nightmare without reverse. What do you guys think should I check/do to fix this hopefully s

Not familiar with 240 Challenger, but............

Start by removing the controls as you did when you replaced the cable. Disconnect the cable and check for ease of movement. Is the cable free? The handle is suspect. There are wires for start-in-gear interlock. Be careful of these. There is usually an adjustment to add drag to the system. This may be overtightened or corroded. The lever itself usually rides on a plastic bushing. Possible corrosion there. There should be a mechanical interlock between shift and throttle. That could be jammed with corrosion. Generally, it's clean and re-lube.

When you replaced the cable, did you replace the rubber bellows at the reverse gate?

 

[nenikol23]

Tim, thank you for your support as always.
I removed the shift cable from the handle assembly, still wasn't able to move the cable by hand. Handle assembly operates very easy and smooth when shift cable is disconnected. Disconnected shift cable from Reverse gate. Shift cable easy to operate. Pretty sure its the reverse gate that is crusted up. I found the two bolts that hold it but there is some sort of pin in the way, so I cannot remove those. Are those just tapered and punched in?

I did replace the belllows when I put in the new shift cable.

 

[poppie]

The pins are pressed in. Tap/pry them out and remove the bolts. Clean everything up and grease it with marine grease. You wont believe the difference when you put it back together. I had the same issue.