1983 merc. small block chevy 228, alpha 1 gen 1 shift shaft inner cable removal..uggg! please help

FORREST3

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Sep 30, 2003
Messages
43
4-5 months rebuilding like new chapparal 198 XLC, engine..transom, ( and surrounding area) resto lower outdrive unit....totally restored interior as new 5 years ago... (I own a shop, do all the work here,)..need to replace bellows now..The shift cable is stumping me..researched and found video that 2 set screws at engine side at plastic sleeve end (it was later model, different type of screw heads), remove plastic "sleeve head",,then slide "inside cable out" from rear of boat.. LOL!! NAHH.. my tiny set screws has 2 tiny square heads on them b.t.w, not hex head like the video. ..inner cable will not slide out.very low houred boat no corrosion btw..Is my earlier model unable to do this? Has to be a way without desrtoying the cable? I would love to be able to remove the bell and do the work easier..shift cable (which works fine btw) is preventing me from moving forward.. any help sure would be appreciated..Just cannot not find same info on this model to do this..Surely I don't have to cut/destroy to remove??I'm about burned out on this boat, been a REAL learning experience!..my expertise is 69-72 Pontiac GTO"S!...thanx!
 
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FORREST3

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Sep 30, 2003
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43
Found another video.. same as my cable..anyway it SHOULD slide out but wont.apparently the set screws were tightened too much and I assume flattened the cable preventing it from sliding out...I'll keep trying.. does anyone know if anybody just sells the inner cable in case I have to cut/drill it out to remove?? > Thanx!
 
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Bondo

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Apr 17, 2002
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71,090
Found another video.. same as my cable..anyway it SHOULD slide out but wont.apparently the set screws were tightened too much and I assume flattened the cable preventing it from sliding out...I'll keep trying.. does anyone know if anybody just sells the inner cable in case I have to cut/drill it out to remove?? > Thanx!
Ayuh,...... They come complete, as a kit,.....
 

MagKarl

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Jan 18, 2021
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I have a similar setup in my boat, square brass set screws. Remove them and then the plastic outer sleeve slides off, right? Do you have a stainless inner sleeve that has the brass barrel nut on it? The stainless sleeve is threaded into the end of the shift cable shell and secured with a jam nut. Have you removed the stainless sleeve?
 

1960 Starflite

Petty Officer 1st Class
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Jun 23, 2011
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386
Sounds like the set screws swedged the OD of cable egg shaped. Possible to file high spots back to round 🤷
 

FORREST3

Seaman Apprentice
Joined
Sep 30, 2003
Messages
43
Thanx guys.. yes they, the set screws were over tightened/"swedged the inner cable TOO much!,,,worked on it for over an hour.. no good, tried everything!, could NOT get it out of the outer plastic sleeve..had to cut at gimble and pull the inner cable out from inside the boat..a shame..It WAS a perfect cable!..The saga continues..
 
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