1986 150 merc xr2 - not engaging gears after new water pump install

Dennis G

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Sep 30, 2004
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It never ends. Engine runs great after new water pump installed. So I just put the muffs back on, start her up, put it in forward gear and it doesn't go into gear. So, evidently, when I replaced lower unit, I didn't do something regarding the gear shift. I'll drop the lower unit tomorrow but I can't find the answer in archives so.....What did I do (or not do) wrong????? I know I took lower unit off in neutral and had to manually turn the flywheel a bit to line up drive shaft. I thought that would take care of business. PS Prop spins freely both directions whether in gear or not
 
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Chris1956

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Mar 25, 2004
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Well, it sounds like you did not mate the upper and lower shift shafts. You should be able to see the coupler on the upper shift shaft.

The fix is to partially lower the gearcase, and mate the shift shafts.....
 

Dennis G

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Hey Chris, Thanks for the reply. Just in from lowering lower unit enough to see that I didn't mate the upper and lower shifts. They are now united. I'm new at this. Before I bolt LU back together, do shift pin at lower unit, shift lever (throttle lever) and drive shaft have to be sync'd in any way? Since dropping and re-installing lower unit, I've moved shift lever, flywheel and prop all over the place. I don't want any bad alignment issues. Thanks, again, for all help. PS I did put a bead of GE silicone on the plate ahead of the water pump between the water pump and the exhaust area.
 
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Dennis G

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Sep 30, 2004
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Hey Chris, Thanks for the reply. Just in from lowering lower unit enough to see that I didn't mate the upper and lower shifts. They are now united. I'm new at this. Before I bolt LU back together, do shift pin at lower unit, shift lever (throttle lever) and drive shaft have to be sync'd in any way? Since dropping and re-installing lower unit, I've moved shift lever, flywheel and prop all over the place. I don't want any bad alignment issues. Thanks, again, for all help. PS I did put a bead of GE silicone on the plate ahead of the water pump between the water pump and the exhaust area.

Update: Lower unit bolted back together. When shift lever at helm is fwd, prop wont turn counter- clockwise (just turning by hand) but will ratchet clockwise (right). When shift lever is in reverse, prop won't turn clockwise but will ratchet counter-clockwise (left). When in neutral, prop turns freely in both directions. I'm assuming /hoping this is all normal. I will not put this pig under power until I here back that this is proper operation. Thanks, again, for all help. DG

Edit: After extensive reading and research, I quess that what I'm hearing / feeling when I turn the prop are the clutch dogs. Older motors had this feature to allow prop to spin upon rapid deceleration. So......I'm quessing that what my outboard is doing is normal. I still would appreciate a verification of this. Thanks, again. DG
 
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Chris1956

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Mar 25, 2004
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Forward operation and neutral operation are fine as you described. I suspect shift cable is mis-adjused, as it seems that reverse is not fully engaging. Set the throttle handle to neutral. Remove the shift cable. Center the shift slide in the neutral detent. Now adjust the shift cable barrel nut until the shift cable installs, without moving the shift slider. If reverse still doesn't work, it may be a gearcase issue.
 

Chris1956

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BTW - normal reverse action is not a rachet. The propshaft would turn less than 1/2 turn in each direction and then engage the clutchdog, locking it to the driveshaft.
 

Dennis G

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Sep 30, 2004
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Thanks for the reply. Greatly appreciated. Will do the checks. DG

Update: My 75 merc is on a boat right next to my Trophy with the 150 xr2 that I'm woking on. I see what you mean by reverse should lock in both directions after a partial turn of the prop. Tried adjusting linkage but still doesnt lock in both directions in reverse. I'm guessing that I should drop lower unit a bit and disengage the lower and upper shift linkage and THEN adjust linkage at the motor. Am I correct in assuming this?? Shifting was fine before I dropped lower unit to replace water pump and I have not engaged shift under power since.
 
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Dennis G

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Sep 30, 2004
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Update: I called Mercury and was told, as I suspected, that the 150 xr2's prop will spin (by hand) in one direction when throttle is in reverse, vs. newer models that will lock up in both directions while in reverse. Case closed
 
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