1990 Bravo 1 - shifter sticky, I made a mistake

[Chap2350]

1990 Chaparral with a Bravo 1 hooked up to 7.4L Mercruiser. Last summer, the shifter was getting sticky going in/out of gear. I'm getting a late start this season, but wanted to find/fix that. So, in my effort to begin troubleshooting, I had shifted it, without the engine running, probably 10-12 times. Now I'm seeing numerous posts/web pages stating that shifting Bravo drives with the engine off should not be done. Great. Now what have I done? Apparently I misinterpreted the warning in my Mercruiser Operation & Maintenance manual which states: "Never shift into or out of gear unless throttle lever is at idle RPM." (I assumed it meant "if the engine is running")

I did not see, and subsequently could not find any other warnings to that effect in either my Clymer Stern Drive shop manual #B742, my Mercruiser Installation Manual for Bravo Models, or the Series 3000 Remote control (the shifter) Installation and Operation Instructions, all of which I had reviewed prior to doing anything.

The stickiness problem appears to possibly be related to the lower shift cable having been "ground down" by contact with the flywheel...so now the inner metal wires on the cable are exposed...I'm guessing this was the result of poor cable routing by the mechanic I had put in the new shifter a few years ago (when I got the boat back, and went to launch, put the boat in reverse, and it went forward...a close call with the guy in front of me - the shop had installed the cables incorrectly).

So now that I operated the shifter w/o the engine running, what should I do?

Thank you in advance for your help and comments.

-Chris

 

[TilliamWe]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

Replace the lower cable. Reinstall the drive properly. Back the trailer down into the water, and while the boat is still securely attached to the trailer (and the tow vehicle is secure on the ramp), start the motor, and try to shift it into forward and reverse. If it works, you're all set. If it doesn't, you have more work to do.

 

[Chap2350]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

Thank you for your advice.

Another thought: Local shop wants about $500 to replace the cable. I'm a little nervous about pulling the drive myself, but have been wanting to be able to take my maintenance ability to the "next level" for some time now.

What could I anticipate as far as the amount of time it will take me to do it (correctly)? Are there special tools needed? Are chances high that one will screw up something else during the process? Any other advice on a successful approach for doing this project?

What say ye gurus?

Thanks again

 

[Bt Doctur]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

http://www.boatfix.com/merc/Servmanl/11/11covr5x.pdf
Make sure you save it too
Just wish I charged that much for a cable.Bravo`s aren`t that difficult, hardest part is removing that heavy, awkward drive.A small floor jack or a hyd engine dolly make it a lot easier to handle

 

[TilliamWe]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

I have never changed a cable, but my dad says it's not too bad. Something about using the old cable to pull the new sheath through, is the key?
And while the drive is heavy (about 150lbs) and awkward, I used to take mine on and off by myself every year. I did eventually buy a real outdrive stand with wheels that made it easier though. It cost around $150. So removing the drive would not be my reason for not doing the work myself. It'll be the easiet part of the job, in my opinion.

 

[Chap2350]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

Thanks guys for the tips. I'm leaning towards trying it myself...

Thank you Bt Doctur for the link.

 

[steinjo]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

I have the same issue and I'm going to try to tackle it myself.

Question: ? :

What else should I inspect / do while I've got the stern drive off, such as the gimbal bearing?

I believe that the lower shift cable comes in a kit. Anyone have a link to purchase? I've used Doug Russel before from a recommendation received here on iboats.

Any insight on other "stuff" that I'll need to put the drive back on? sealant, grease, etc. ?

 

[TilliamWe]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

You don't "need" anything to put a Bravo back on. Allt he O-Rings should not be damaged from removal. You could buy a set of them, if you really want to spend another $17. I had my Bravo 3 off/on at least 10 time, before i ever changed the o-rings. You'll want to grease the splines of the driveshaft prior to re-installation.
Gimbal bearing is a good thing to check, along with the driveshaft bellows. Also grease the u-joints, if they are greaseable. (My 1997s were, but later years, they are not)

Just remember, when putting the drive back on, make sure the "jaws" of the cable in the drive stay open, and close around the round knob on the cable in the transom housing. It's easy to bump those jaws closed, and if you do, it'll mean you'll be pulling the drive off again.

 

[flargin]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

check and replace if needed the shift cable bellows. they can go bad and let water into the bilge.

ditto the point of making sure the jaws of the shift clamp stay out... you WILL hit it wrong at least once!!! so be ready for it. not hard to do, just watch it like a hawk.

 

[Lou C]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

I built this out of left over 2x6s and I got some adjustable casters from Home Depot and mounted them underneath so I can get the height exactly right....works great with my OMC Cobra.....a Bravo looks pretty heavy if you have a bad back you might want to build one of these first...it also makes it much easier to get it back on.....

 

[TilliamWe]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

Bravo drives weigh in the neighborhood of 150lbs. Give or take a ruptured disc or two.

 

[Lou C]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

I'd guess a Cobra only weighs about 80-90 lbs or so...I was able to lift it up without too much trouble when I had to flip it over to flush the barnacles out of the water intakes...but when you are trying to get the drive shaft in...and keeping it all lined up...because you are leaning over it...pretty easy to just twist the wrong way and ruin your day.....so I'd tell anyone take a couple of hrs and build a nice outdrive cart...with casters so you can roll it into the garage for the winter....

 

[steinjo]

Re: 1990 Bravo 1 - shifter sticky, I made a mistake

Need some help:

- Have a 1996 Bravo One

- Put it in the water and moved shift lever into forward and nothing happened.

- Put in reverse and it worked. Then moved shift lever into -N- but it stayed in reverse. Moved into -F- and was still in reverse.

- Thought that the cable came out of the shift jaws so I pulled the drive, made sure the jaws were "closed" around the cable when I reinstalled.

- As the drive was off I moved the shift lever handle from N to F to R and it appeared to be moving correctly.

- When I started the engine it was in neutral like it was supposed to be. Put in F and nothing (same problem as before)

- Put in -R- and it went in smoothly.

- Moved to -N- but it stayed in Reverse...

- Shut down and restarted and the shift lever moved the drive into -N- but no luck going into -F-. Moved into -R- and once again became stuck there.

Don't know if it's a cable adjustment or problem with the shifter itself.

Any ideas what to "test" next?