Alpha One Bad Grinding In Forward Gear

[shekinah5678]

Hello all.
I am new to creating posts but have been reading the forum for years.
First of all I have a 1992 Crownline with the 4.3 LX mercrusier and Alpha one drive. I've had the boat for about 6 years now. I just went out and started her after a long winter and all was well until I tried to put it in gear. When I shifted it into forward gear it grinded very loudly and the grinding didn't go away until the RPMs increased significantly. I?m not sure if they went away then or the engine noise drowned it out. I did this all in the drive way with the ear muffs on so I have no idea if the boat would actually move or not. I did take notice that the propeller was moving. I tried shifting it to neutral and back to forward with no change in the grinding noise. I also turned the motor off and checked the prop seemed to turn fine in neutral and caught and held strong in gear. I did notice a slight movement of the prop shaft forward and back only maybe an eighth of an inch. I think that play has always been there. I Didn't let it grind long maybe 30 seconds so I?m hoping I haven?t caused any further damage. When I shifted into Reverse it worked fine no grinding except the usual quick clunk sound. I have read other posts that indicated either a faulty or out of adjustment lower shift cable. None of the posts that I could find had my problem of continuing to grind until shifting back to neutral. Are there any other more likely explanations? I would note that the boat shifted just fine when taken out of the water last fall. Could the shift cable do this over the winter without any use? How would I go about adjusting it? Is that something a novice mechanic such as myself could do? Any and all input would be very helpful.

Thanks Very Much

 

[Bondo]

Re: Alpha One Bad Grinding In Forward Gear

Could the shift cable do this over the winter without any use? How would I go about adjusting it?

Ayuh,... Welcome Aboard,... I think it's time to Replace it, I doubt adjusting will fix anything...

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

Thanks Bond-O
I talked to a local marine mechanic who said he could change the bellows and shift cable for about $600.00 including parts. Does that sound like a reasonable price? I thought about doing the work myself but I'm a little nervous considering the boat could sink if done wrong and the cost of the special tools is about an extra $150.00. I'm still scared that I'll pay $600.00 for this work and it won't be the problem. I've read so many posts describing a faulty shift cable and none really describe my problem. Can you think of any other things that could explain this problem?

 

[bigskiohio]

Re: Alpha One Bad Grinding In Forward Gear

is it a grinding or more of a clacking like it is not going in gear fully.
$600.00 is not to bad for someone to do the work call around .but you could try yourself alot have done this without special tools except $ 40.00 alignment tool that you need anyways if you own a boat.

 

[ENSIGN]

Re: Alpha One Bad Grinding In Forward Gear

I'm surprised you don't also have a stalling problem.The cables wiil hang up after sitting.With the proper tools the job is not that hard and 600 bucks sounds kinda high for a shift cable kit and labor.I do this every day,hope this helps,Ted

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

bigskiohio; It definitely could be a clacking noise and it seemed like it wasn't going all the way into gear. To ENSIGN the motor did seem to want to stall when put down at idle speed while in forward gear. Didn't let it stall though just shifted back to neutral before I could do any damage. What puzzles me is it shifting into reverse the same as it always has. When a shift cable goes can it just affect one gear and not both? The $600.00 was for Bellows and shift cable.

Thanks for the replies

 

[Fishermark]

Re: Alpha One Bad Grinding In Forward Gear

When a shift cable goes can it just affect one gear and not both?

Yes it can.

Before spending $600 I would certainly suggest adjusting the shift cable. It costs you nothing but a little time - and it can save you a ton of money if that turns out to be the problem.

Of course if your bellows are old... then it is time to go ahead and change them out before they cause bigger (more expensive) problems.

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

I think I will try to adjust first if for no other reason than to make my wife happy. I know it's probably a long shot but why not. Bellows seem to be in pretty good shape no cracking or dry rot that I can see. But I figured if the shift cable is getting done why not do it all?
Thanks again to all.

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

Update

I just finished trying to adjust my lower shift cable. I have a mercruiser service manual but to be honest it was a little vague when it came to this. Anyway I quickly found out that the actual shift cable has no real adjustment and that it is the cable going to the control that must be adjusted. Adjusted as far as I could in the forward direction without triggering the interrupt switch. I then started the motor and attempted to shift with no change. The good news, at least in my mind, is that I then removed just the shift cable and manually shifted it into gear. It shifted seamlessly with only the quick grinding sound (the sound it has always made and that I think is normal) and it was in gear. I was worried about major outdrive problems but I think that alleviates those fears. I also took a good look at the bellows and they all look fine no dry rotting or cracks at least that I could see. Since I'm having the shift cable replaced should just go ahead and pay for the bellows to, or is it something that I could save a little money on for now?

Sorry so long winded and again thanks to all!!

 

[Fishermark]

Re: Alpha One Bad Grinding In Forward Gear

Anyway I quickly found out that the actual shift cable has no real adjustment and that it is the cable going to the control that must be adjusted.

That's not totally accurate. You need to adjust (or set) it to exactly six inches. Then you adjust the control cable to match. There is some fine tuning that can be accomplished from there.

Is that what you did?

 

[wil7483]

Re: Alpha One Bad Grinding In Forward Gear

I'm no expert but the shift cable is adjustable. Whenever it is replaced it has to be adjusted as well. The cable going to the control usually doesn't need any adjusting once it is installed. Replacing the shift cable isn't all that hard a job and you could have it done in about 3 hours.

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

The Brass Barrel on the shift cable that threads back and forth has two little indentations that look like some kind of tool was used to crimp it in that exact location. I tried to turn it but it was locked in that exact location. I even used two pairs of pliers to try and break it loose. Although I must admit when it didn't want to give I stopped and assumed that the cable was not meant to be adjusted. I didn't measure it but it looked like it was about six inches. Is there some method to getting it to turn? I will try to take some pictures and post them later.

Thanks Again

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

Ok I have taken the time to closely read and understand the service manual along with several online posts and articles decribing replacing the shift cable. I am a lot more confident that I can change the cable myself as a few have told me here. I have ordered the cable kit that comes with new cable bellows and the bellhousing gaskets and orings. I have also ordered an alignment tool, hinge pin tool, and the cable installation socket. Can anyone think of anything else I will need? Also are there any little hints or suggestion that are wise to do or will make the job a little easier? As I said before the ujoint and exhaust bellows look good so unless the joints are rusted or I find water I'm gonna hold off on those for now.
Thanks Again

 

[fishrdan]

Re: Alpha One Bad Grinding In Forward Gear

Did you order a "Mercruiser / QuickSilver" lower shift cable kit, the real McCoy, not an aftermarket kit? I will never buy an aftermarket lower shift cable again after using the Mercruiser cable, really it's worth the extra expense.

If it's been 4-5 years since the bellows were replaced I would do them at the same time as the lower shift cable. If you wait for them to go bad you will have a much steeper repair bill, Ujoints, gimble bearing.........

 

[shekinah5678]

Re: Alpha One Bad Grinding In Forward Gear

OK Everyone I started the job today. I decided to go ahead and replace the bellows to while I'm doing it. I haven't received any of the parts yet but they should be here any day so I went ahead and started by removing the drive. All went really well so far. Drive came rite off with very little pulling. The U-joints look very good no rust and lots of fresh grease on them. So I think I'll leave them alone. The gimbal bearing turns freely no binding and also had lots of grease on and around it. I want to leave it alone to because everything I've read on this site suggests it can be a p.i.t.a. to replace. Plus I don't have any of the tools to take it out or install it. While I was pulling the drive the UPS guy delivered my Engine alignment tool. So I slid it in and checked that. I haven't gone through the whole engine alignment process but it seemed fine. The tool slid rite in with no resistance. One thing I'm not clear on is how the shift cable comes out of the boat. Once I disconnect it from the bell housing and the shift bellows can I pull the cable out from the outside? Also I assume the new cable will install back through the transom the same way? But once it's through how do you get to it to pull through. That seems almost impossible without pulling the motor.
Sorry to ramble on I just get caught up thinking of one more thing to ask. Fishrdan to answer your question I'm not sure if it's an aftermarket cable kit or not. Here is the ebay auction title. "Mercruiser Alpha I Gen 2 Lower Shift Cable Kit 18-2603."

Thanks to everyone You've been really helpful.

 

[bds85466]

Re: Alpha One Bad Grinding In Forward Gear

I've read that sometimes there's a plastic spiral wrap on the sheath (on the inside of the boat) to protect the cable from melting to any exhaust components. Reach down along the cable as far as you can to make sure this isn't still there. If it is, remove it.

Turn your steering left, and use your sweet* 9/16" socket to remove the cable sheath from the bell housing. After it's all the way unthreaded, the cable should just pull out -- ASSUMING, you pulled that plastic spiral wrap. I've heard if you forget that step, it's a real pain as it will wedge itself in place...

*by "sweet" I mean specialized or modified...

 

[bigskiohio]

Re: Alpha One Bad Grinding In Forward Gear

when mine was clacking in reverse i just slid the barrel so that it would engage more and that fixed it. I think the six inches gets you close then you fine adjust it .i did it on the water moved while somebody held prop in reverse.

 

[bds85466]

Re: Alpha One Bad Grinding In Forward Gear

And, just a question out of pure curiosity:

How much "grinding" is too much? I mean, it can't be great for the clutch or the gears and it's best to keep your shifting tight and smooth, but are they pretty robust? Grinding just means that the cable ultimately isn't giving the clutch dog enough travel?

I've been on some peoples boats saying they've been grinding for years!

 

[Bondo]

Re: Alpha One Bad Grinding In Forward Gear

How much "grinding" is too much?

Ayuh,... Any grinding is Too much...
Dog-clutched drives need to be shifted "Briskly"... there should be a Single, "Clunk"....

No Grinding at All...

 

[fishrdan]

Re: Alpha One Bad Grinding In Forward Gear

"Mercruiser Alpha I Gen 2 Lower Shift Cable Kit 18-2603."

That's a Sierra (aftermarket) lower shift cable. I've used a couple of aftermarkets with mixed results, but after using and seeing the difference between the Mercruiser/Quicksilver cable and the aftermarket, I won't use an aftermarket anymore.

Did you download the correct Mercruiser repair manual up in the adults section for your outdrive? It will have all the info for installing the cable and bellows. Did you get the bellow tool for the exhaust bellow, it's a real *&#@ without the bellow expansion tool, darn near impossible. I cobbled something up as I didn't have the tool, worked pretty good too. If you don't have the tool, let me know and I'll show you what I came up with.

On removing the lower shift cable from the bell housing, it will slide right out,,,, after you remove the end of the cable (plastic end, metal tube, nut and barrel nut) that's inside the boat, and the spiral wrap. Have fun getting the new cable through the bellow...