Slipping Out of Gear - Bad Coupler?

[myfirstboat1984]

I recently posted this information with a title of "Lower Unit Problems", but I wanted to repost with this title, because I am starting to think this could be a bad coupler problem. A local mechanic has gotten me to start thinking this could be the problem. The reason he is leaning towards this is because there is seemingly no power at all getting to the lower unit and also, the impeller is seemingly not getting any power (at least it's not pumping water, even with muffs on). Maybe the problem is closer to the engine?

Below is all the info. Is there an official test for a bad coupler that I can perform?


"I have a 1984 Wellcraft, with a mercusry mercruiser inboard/outboard, 4 Cyl, 140 HP, 3L Engine. Several times over the last couple months, the boat has slipped out of gear. Before, I was able to get it back in gear, but this time, I was not. I am not able to get any forward or reverse now. Here's what I know...

-Drained oil. There are small medal shaving in oil. Enough to be noticable. This oil was changed a month ago.

-With engine on, from control panel, shift to forward or reverse, and there is absolutely no gear sounds at all in the lower unit. No grinding, but the shift cable is moving and the linkage is intact all the way to the lower unit.

-With the engine off, shift to forward. I cannot turn the propellor in the reverse direction, but I can turn it in the forward direction easily. When I do, there is a click noise about midway up the lower unit.

-with the engine off, shift to reverse. I can turn the prop both directions easily, and the click mentioned about doesn't happen, but there is some very slight clicking at the lower part of the unit, near the prop.

- Maybe related?? The empellor is no longer pumping any water through the engine (using muffs)."

 

[Don S]

Re: Slipping Out of Gear - Bad Coupler?

Look at the back of the engine where the shaft from the outdrive goes in the coupler. See metal shavings??? If so, you need a coupler. If not, have someone crank the engine over (don't need to start it) and see if the shaft is turning. If not, you need a coupler. If the sharft is turning pull the top cap on the outdrive and look at the gears.

 

[bigskiohio]

Re: Slipping Out of Gear - Bad Coupler?

mine made a rubber squeak when cranking engine , mine had splines loose from rubber. I paid 85.00 for a new one , easy job to do even though motor has to come out. could be you cable maybe or outdrive as i cant see coupler work then not work. Take the out drive off and you will see melted rubber if it is your coupler and also you will smell rubber when it went out. check you cable adjustment,sound like you are not engaging fully.

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

Tonight, I put the boat into forward, then tried to move the prop counterclockwise. I was afraid to turn it hard the other night, but after reading some other posts, I wanted to try and crank it hard, and even crank the engine a bit (it can do that I think?).

It turned somewhat easily! With a little effort, I was able to move it. As I posted already, in reverse, there is almost no resistance either way. So I took your advice, and I took the top off the upper unit. There are two large gears there, meeting up to each other. One is damaged, but has gear teeth left. The other is nearly completely bare. I confirmed that the verticle shaft was turning when I turned the prop, but the horizontal one was not. It is completely stripped.(See attached image)

Of course, the entire shaft was full of medal shavings. What do I do now?

 

[dubs283]

Re: Slipping Out of Gear - Bad Coupler?

time to rebuild or replace the upper half of the drive

then dissasemble, clean and inspect the lower for damage

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

Thinking about cost... Probably a dumb question. Can I replace only certain parts now without damaging the new ones? Maybe an upper unit rebuild only for now? One of those gears had a nut to release it, but the other one seemed to be attached to the verticle shaft permanently. That shaft runs the length of the upper and lower, or just the upper?

I know, I need to get out my manual now...

 

[180shabah]

Re: Slipping Out of Gear - Bad Coupler?

Those metal bits are all through the drive - really needs to be all or nothing at this point.

Check out SEI - they are available right here at iboats.

 

[dubs283]

Re: Slipping Out of Gear - Bad Coupler?

no the gear set needs to be replaced, both gears, and shimmed

you will need the special tools if you do it yourself

the upper driveshaft is independent of the lower driveshaft, they are connected by splines

this is to allow the separation of the halves to service the water pump, etc.

 

[Bt Doctur]

Re: Slipping Out of Gear - Bad Coupler?

Usually caused by a lack of oil,if the gears have not cut thru the case you may need gears,bearingsm and seals. If the case was "holed" ,you need a new upper unit.

Those teeth you see on the bottom part will cut a hole right thru the aluminum

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

What is SEI?

 

[bigskiohio]

Re: Slipping Out of Gear - Bad Coupler?

cheap aftermarket outdrive with 3yr. warranty, cheaper then reworking your unit and faster . or just find a used one.

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

Oh boy. Thanks for all your help guys. I'll let you know how I proceed.

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

I am tearing the upper unit apart now, to get more info of the damage. I've removed the upper and lower unit. I've removed the drive shaft from the upper unit (well, the part with the U-Joint). Now, shouldn't I be able to pull the other gear assembly straight out the top? It's not coming out, but I wonder if the worn gears eating into the casing, as mentioned above, might be causing this to be stuck?

Also, I was having an oil leak from the upper (maybe the cause of these gears getting ruined in the first place). Could the oil seals in this assembly be causing a leak that I would have seen from the outside of the unit before? I could see it drip off the back of it, near the shift lever thing.

Not sure if I said already, but this is an Alpha Drive, 1984.

 

[Gary H NC]

Re: Slipping Out of Gear - Bad Coupler?

Why tear it apart when you have no special tools required or the knowledge to fix it?
Find a good used drive or look at the SEI drives for replacement.
By the looks of the gears the whole thing would make a good anchor..
There is metal shavings throughout the whole drive so more than likely other gears in the lower are damaged.

 

[SS MAYFLOAT]

Re: Slipping Out of Gear - Bad Coupler?

Why tear it apart when you have no special tools required or the knowledge to fix it?
Find a good used drive or look at the SEI drives for replacement.
By the looks of the gears the whole thing would make a good anchor..
There is metal shavings throughout the whole drive so more than likely other gears in the lower are damaged.

Excellent advice. About 18 years ago before iboats, I went through the same thing you did or want to do. I bought a new upper case, gears, seals, and shafts. Rebuilt the lower as well and after it was all done,,,,,I spent way more money on it than using it as a core to get another plus not counting the numerous phone calls, part runs, and time out of the water. Then afterward, I never felt comfortable with it even though it made no noise and ran smooth. I saw the boat a while back on the lake and it is still running and sounding great. It still had the same outdrive that I had rebuilt. Give it some thought as being out on the lake or river is no place to find out that something didn't go right. And if it does go wrong, your out the money vs the warranty of a remanufactured or aftermarket one.......SS

 

[Bondo]

Re: Slipping Out of Gear - Bad Coupler?

Why tear it apart when you have no special tools required or the knowledge to fix it?

Ayuh,.... That drive is Junk,....
Maybe a couple bucks as a Core to a drive Rebuilder,... Probably Not...

You need a Replacement Drive,....
A New SEI is the Wisest money spent....
Rebuild Mercs cost as much or more,... New is Out of the question....

 

[Cptkid570]

Re: Slipping Out of Gear - Bad Coupler?

You can find more info on a SEI drive (aftermarket Mercruiser outdrive) here:

http://www.sterndrive.cc/index.htm

You can buy a whole drive or just the upper.

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

do I risk major damage to the lower, if I only purchase the upper? I hate to even ask, cause I know there are medal shaving all through the lower, but since the last post mentioned the upper only... $600 might be a doable thing for me this year.

 

[180shabah]

Re: Slipping Out of Gear - Bad Coupler?

Your lower has already had all that loose metal circulating through it for a while now, accelerating wear to the gears there. It is still in there, and draining will not remove all of the shavings. You risk an early death to your new upper by not dealing with the lower now.

 

[myfirstboat1984]

Re: Slipping Out of Gear - Bad Coupler?

Just wanted to bring this post to a conclusion. I gave up on trying to replace the gears myself. It's too hard! Still, I learned a lot about the inside of that thing, and hopefully that will help me in the future.

I bought a new drive and it arrives in two days.

Thanks to all for the advice.