Cable won't move! How to get drive into forward?

[smithrock]

Re: Cable won't move! How to get drive into forward?

I drained what I thought was quite a lot from the lower drive before I removed it. but when I pulled the upper, there was alot in there. Does oil usually sit in the bellow? Also I noticed that the O-ring that goes to the water intake wasn't seated real well, it's too big to go back in and fit right. Maybe I was getting a little water in there as well? The oil that came out was black and sludgy.

Here are the pics. Hard to tell but the oil is thick and it smells like gear oil.

oil looks brown in the sunlight

in this one the oil is pouring from the shift slide.

in this one the oil is sitting in the bellow

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

No,... It Leaked from the Outdrive.....

So is that a problem?

 

[Don S]

Re: Cable won't move! How to get drive into forward?

Of course it's a problem. First of all the oil is burned, way overheated.

How long since it was last changed? Do you do a lot of very long runs while on plane.
The reason there is gear lube in the bellows is either the front seal, the ujoint yoke or probably boat are bad and in need of rreplacement.

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

Of course it's a problem. First of all the oil is burned, way overheated.

How long since it was last changed? Do you do a lot of very long runs while on plane.
The reason there is gear lube in the bellows is either the front seal, the ujoint yoke or probably boat are bad and in need of rreplacement.

Not sure when it was last changed. I know I changed the lower approx 2 1/2 years ago, when I installed the new water pump I do long runs on plane when we're wake boarding or flying through Marine Stadium. Is there a way to tell which is bad (front seal, or yoke)?

I did get the shift cable removed!

The sheathing on the cable must have been rubbing on the Y-pipe exhaust, it's totally worn and corroded. After I removed it I pulled the cable out od the sheathing, it was a little tight. I tried running the cable back through-but no way! It wouldn't go more that about 5 inch before stopping! I think it's dust! I did measure the cable itself, it's 6' I'm thinking of putting in a longer one probably 7' to eliminate the rubbing, so I can route it better.

 

[dubs283]

Re: Cable won't move! How to get drive into forward?

the shift cable you get from mercury is a specific length and designed specifically for alpha drives

the routing is very important and needs to be correct

manual #14 has pictures in it for different motors and how the cable MUST be routed

since the cable is already out it is too late for you to connect a fish tape to the old cable, this really helps in pulling the new one

you should reconnect the halves of the drive and pressure test it, this will allow you to pinpoint the seal that is leaking

 

[Don S]

Re: Cable won't move! How to get drive into forward?

Not sure when it was last changed. I know I changed the lower approx 2 1/2 years ago,

Recommended is yearly or every 100 hours. Which ever comes first. With the type of running you do, yearly would be a very, VERY good idea.
All that maintenance stuff is not just meant for someone else.

Is there a way to tell which is bad (front seal, or yoke)?

You know it leaks, cause there is oil in the bellows. Pull it apart and look at the yoke if there isn't a groove worn in it from the seal, and it's not all rusty, it's fine.
Then, replace the seal no matter what.

I tried running the cable back through-but no way! It wouldn't go more that about 5 inch before stopping! I think it's dust! I did measure the cable itself, it's 6' I'm thinking of putting in a longer one probably 7' to eliminate the rubbing, so I can route it better.

Hate to be the one to tell you this, but they only come in one size. Get the OEM shift cable, install it "BY THE OEM MANUAL" including the sprial wrap, route it per the manual, and it will be fine for many years.

There is a reason for all the parts in the kit and a reason the manual tells how to put it together a certain way.
Use that information.

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

the shift cable you get from mercury is a specific length and designed specifically for alpha drives

the routing is very important and needs to be correct

manual #14 has pictures in it for different motors and how the cable MUST be routed

since the cable is already out it is too late for you to connect a fish tape to the old cable, this really helps in pulling the new one

you should reconnect the halves of the drive and pressure test it, this will allow you to pinpoint the seal that is leaking

I'm going to install a whole new cable and sheathing.

I have Mercruiser Service Manual #6 I'm looking at page 3B-10 Which is the Front Seal? Or if anyone has a simplfied diagram?

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

Recommended is yearly or every 100 hours. Which ever comes first. With the type of running you do, yearly would be a very, VERY good idea.
All that maintenance stuff is not just meant for someone else.



You know it leaks, cause there is oil in the bellows. Pull it apart and look at the yoke if there isn't a groove worn in it from the seal, and it's not all rusty, it's fine.
Then, replace the seal no matter what.



Hate to be the one to tell you this, but they only come in one size. Get the OEM shift cable, install it "BY THE OEM MANUAL" including the sprial wrap, route it per the manual, and it will be fine for many years.

There is a reason for all the parts in the kit and a reason the manual tells how to put it together a certain way.
Use that information.

Ok. what manual # is it in?

The yoke looks good. Where is the seal? I see a lot of different seals in the manual

 

[Don S]

Re: Cable won't move! How to get drive into forward?

The yoke looks good. Where is the seal? I see a lot of different seals in the manual

Do you have the yoke removed from the double beaings?

Ok. what manual # is it in?

Have no idea, you say an Alpha I, but is it, or is it a Gen II, MR, R, 1 drive ??????? Got a SN? Even a year may help narrow it down.

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

Do you have the yoke removed from the double beaings?



Have no idea, you say an Alpha I, but is it, or is it a Gen II, MR, R, 1 drive ??????? Got a SN? Even a year may help narrow it down.

No, it's not removed from the bearings. I thought the yoke is the shaft connected to the U-joints?

My Sterndrive serial # is: 6884096
Gear ratio: 1.84 R

Do you happen to have a part # for the correct cable? If my previous cable was rubbing won't the new one?

 

[Don S]

Re: Cable won't move! How to get drive into forward?

Head up to the Adults Only sticky at the top of the page, go to Merc service manual link and find manual #6.
It will answer your questions,

If my previous cable was rubbing won't the new one?

Section 4A is going to be your friend. The spiral wrap prevents the wear.

865436A03 is the cable kit you want. Includes shift cable bellows.

PS: Get the OEM kit not those junky aftermarket cables.

 

[dubs283]

Re: Cable won't move! How to get drive into forward?

yes, yoke shaft is connected to the u-joints on the outside of the drive

i thnik don was reffering to the double bearing set on the inside of the drive

the only way to inspect the yoke shaft for grooves is to disassemble the drive and remove it

merc dealer will give you the right cable kit

could be the old cable was routed wrong, overheated and melted, or just original and very old

the white coil wrap that comes with the new cable kit will prevent chaffing on the outer cable

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

Head up to the Adults Only sticky at the top of the page, go to Merc service manual link and find manual #6.
It will answer your questions,


Section 4A is going to be your friend. The spiral wrap prevents the wear.

865436A03 is the cable kit you want. Includes shift cable bellows.

PS: Get the OEM kit not those junky aftermarket cables.

I do have manual #6 in hard copy that I've been using. But I still am unable to find the "front seal" that you mentioned.
Thank you for the part # for the cable. I am also going to need a water passage O-ring, is there a part # for that?


Don,
Is there not suppose to be any gear oil in the upper drive bellow? Reason I'm asking is, when I drained the lower I had the trim all the way up. If it was down would the upper have drained as well?

 

[Bondo]

Re: Cable won't move! How to get drive into forward?

Is there not suppose to be any gear oil in the upper drive bellow?

Ayuh,.... As has been REPEATEDLY Stated in this thread,..... NO....

 

[Cptkid570]

Re: Cable won't move! How to get drive into forward?

The O-ring for the water inlet comes with the gasket kit for the reinstallation of the drive. the kit costs like $7 or $8

If you want to find your exact leak, as suggested before, you need to pressure test the drive. If I'm right here, it's not as hard as you may think. You leave the oil vent screw (on the upper drive) in, and pump air into the hole for the lower/oil fill screw in the lower drive. You can probably get away with just using a bike pump with a plastic attachment (that usually comes with a pump when you buy one - probably used for blowing up rafts or pool toys). They guys on here will correct me if I'm wrong about that.. but it worked for me.

 

[ziggy]

Re: Cable won't move! How to get drive into forward?

But I still am unable to find the "front seal" that you mentioned.

a pic of the ft. seal on a 1 drive. your's should be similar.

the sequence of parts.

your's should be similar. may not have the small spacer washer, the smallest ring in the pic. the seal is 2nd from the right..

the yoke

complete with a rust groove wore in the yoke from the water that intruded my drive.

the yoke, brgs and seal were replaced in this drive. yoke for rust, seal because i was there and the brgs because they were blue...

this is what you need to go look at to see that seal..

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

a pic of the ft. seal on a 1 drive. your's should be similar.

the sequence of parts.

your's should be similar. may not have the small spacer washer, the smallest ring in the pic. the seal is 2nd from the right..

the yoke

complete with a rust groove wore in the yoke from the water that intruded my drive.

the yoke, brgs and seal were replaced in this drive. yoke for rust, seal because i was there and the brgs because they were blue...

this is what you need to go look at to see that seal..

Ok. thanks for the pics. How difficult is it to get to that front seal and replace it?

 

[JustJason]

Re: Cable won't move! How to get drive into forward?

its not to difficult if you have all the tools. You need a retainer nut wrench from Merc, a clicker torque wrech, a dial indicating torque wrench, a dial indicator, an upper shim gauge, feeler gauges (extra long preferred) A way to flip and hold the drive upside down. A spline socket to spin it all to check your bearings...... Am I missing anything here guys?

Or you can just throw it all together and hope for the best.

 

[bigskiohio]

Re: Cable won't move! How to get drive into forward?

question ,instead of the shim gauge is it possible to use gear blueing and adjust until the marks are centered.

 

[smithrock]

Re: Cable won't move! How to get drive into forward?

Head up to the Adults Only sticky at the top of the page, go to Merc service manual link and find manual #6.
It will answer your questions,


Section 4A is going to be your friend. The spiral wrap prevents the wear.

865436A03 is the cable kit you want. Includes shift cable bellows.

PS: Get the OEM kit not those junky aftermarket cables.

I did find OEM Mercruiser shift cable online. iboats doesn't sell OEM? I checked it and they have Sierra and Mallory. Is the Sierra kit just as good? If so, which part # for that kit?