Shifting Problems Johnson GT150

[kmaglothin]

This may be a little hard to describe so bear with me. I have used the part descriptions from the parts manual for the motor. After reinstalling the lower unit and inserting the shift rod into the shift rod lever assembly and installing the pin the motor would not go into forward. The shift rod adjustment (length) was not changed and the rod is facing forward. The adjustment on the shifting cables were not changed. In other words all is the exact same as it was when it worked. The only thing I could find was that the bolt on the top of the shift rod lever assy that the shift rod fits into was very loose. I am wondering if this could have allowed the shift rod lever to rotate. I have checked the service manual and there is nothing that I could find that tells you how to adjust the shift lever in relation to this assembly. Is there a procedure to do this? Another potential indication of the problem is that when in reverse the shift arm assembly does not travel to the stop. Is is about an inch away from the stop. Not sure if it is supposed to hit the stop or not though. (whew...that was tough to describe!)

 

[Dhadley]

Re: Shifting Problems Johnson GT150

There is a specific shift rod height that must be set when you replace the unit. The rod can turn when dropping or replacing the unit. Believe it or not, since the rod is not seated many people seat the rod thinking thats correct. I've even seen a buddy screw the shaft down because he thought it was loose.<br /><br />We probably need to start from scratch and drop the unit and set the shift rod height as per the manual.<br /><br />Good luck!

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

The thing is...it isn't the rod height that is the problem...it is correct per the manual. The problem is, I believe, that the assy that the rod connects into has moved on the shift lever which changes how far the shift cable moves the rod up and down. Think of it this way. You move the remote handle (throttle and shift control in the cockpit) the shift and throttle cables move the spark advance and throttles and the shift lever...the shift lever moves the assembly that the shift rod is attached to and the assy moves the shift rod up and down in the gear box. I think that what has happened is that the assy that holds the shift rod has rotated on the shift lever which has changed how far the rod moves up and down. What I am trying to figure out is...if everything is correct...how do I determine when the shift lever is in the correct position relative to the cables...should the shift lever be against the stop when in revers for example? I know this is confusing and I apologize for that.

 

[Dhadley]

Re: Shifting Problems Johnson GT150

Did you remove the clevis from the shift linkage under the carbs?

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

The clevis was not removed but during the reinstall I found that the bolt that holds that clevis on the shift lever was very loose. Additionally, it is the position of that clevis on the shift lever that I need to correct.

 

[Dhadley]

Re: Shifting Problems Johnson GT150

That clevis only fits on the shaft in one position.

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

Hmm...that makes it more interesting. Back to the drawing board then. So to clarify what you are saying...the clevis cannot rotate into another location? If this is the case...I have no idea what else could have happened since I have verified that everything else is where it should be.

 

[Dhadley]

Re: Shifting Problems Johnson GT150

When you measured the shift rod height, was the unit in neutral or in gear?

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

It was in neutral.

 

[Dhadley]

Re: Shifting Problems Johnson GT150

As long as you used the measurement for a crossflow 150 and not a looper 150 it should work. A sign is that when the lower unit is installed and the shift pin in, the arm (that the cable hooks to) should be straight up and down. <br /><br />If it is, and you can shift it by hand, then the problem is from there forward.<br /><br />If its not pretty much straight up and down then the problem is in the shift rod height as long as the shift linkage is in line like it should be.

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

Shift rod is straight up and down...that is why I am suspecting that somehow the clevis has shifted on the shift lever.

 

[Dhadley]

Re: Shifting Problems Johnson GT150

With the cable off, does it shift properly by hand?

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

Yes it does. The problem only happens when all linkage is connected then the restriction happens.

 

[Dhadley]

Re: Shifting Problems Johnson GT150

If the problem only occors after the cable is connected then the problem is from the connection forward.<br /><br />Gotta ask a silly question -- are we sure we're trying to hook the correct cable to the shift? I'm sure we are but sometimes ya just gotta ask........

 

[Dhadley]

Re: Shifting Problems Johnson GT150

OK another scenario -- what if it (shift shaft) was off to start (previous owner/repair) with and you corrected it when you had the lower off? The cables may have been way out of normal adjustment but working. You fixed the shift shaft dimension but now the cable needs re-centering.

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

Yes, correct cables...not a silly question...I am sure I am capable of doing something like that.(Grin) I am the original owner and the lower unit has never been off the motor. I am home now and going to go after it again...maybe something will show up that I have missed.

 

[kmaglothin]

Re: Shifting Problems Johnson GT150

Got it! Found out the gears had not messed when put back together. I had checked for this but for some reason it took a little bit more force to get the gears to mesh. As soon as I rotated the prop I heard them fall into place and then tested the shifting...a smooth as could be. Thanks for the help.