1988 80hp 3cyl upper shift shaft stuck UP against powerhead

[Dallenx]

Mercury OB195172
The upper shift shaft has ridden up against the powerhead and I could not shift.
A large flat screwdriver was used to pry the shaft down and I was able to shift between gears.
I'd like to find out why it happened.
I've searched the forums and online videos and parts diagram and I haven't found anything.
I don't see on the diagram where there might be a missing C-clip.
My repair manual is of no help.

 

[Dallenx]

Re: 1988 80hp 3cyl upper shift shaft stuck UP against powerhead

The upper shift shaft, when the LU is dropped and the shift arms are off, is very hard to turn.
The upper shift shaft is centered as it enters the upper part of the pivot (steering) tube but the shaft is rubbing against the back of the tube as the shaft comes out the bottom.
I'm wondering if this is causing the shift shaft to ride up when I steering or tilt the motor.
The lower motor mounts don't look to be damaged in a way that could cause this type of position.
Any ideas? It almost looks like it should be this way because there's just enough room for the reverse lock rod (which mine does not have) to fit inside the pivot / steering tube.
Here's a thought; is the upper part of the upper shift shaft 'not' supposed to be centered at the top of the steering tube?
If I grab the engine from the top or bottom and give it a good wiggle I only see a little 1/16" of movement from the top motor mounts and nothing from the bottom.
Does anybody have a 75, 80 or 90hp from around 1988 and they could look at their shift shaft?

 

[Chris1956]

Re: 1988 80hp 3cyl upper shift shaft stuck UP against powerhead

The shift shaft should be loose inside the steering pivot rod. Is it still mated with the lower shift shaft? Normally the upper shift shaft will be forced up, when you re-install the gearcase, and the two shift shafts are not mated properly.

Alternatively, I suppose corrosion could jamb the shift shaft inside the steering pivot rod. Did this just come on, or what?

 

[Dallenx]

Re: 1988 80hp 3cyl upper shift shaft stuck UP against powerhead

It mates to the lower shift shaft coupler ok.
Checked everything the other day, trailered 20mi to go fishing, backed away from the dock then it won't go into drive.
Got the kicker going and motored back to the dock.
Found the upper shaft was logged against the powerhead again.
It's coming down to:
1. Teflon bushing is not so slick any more (sprayed it and it helped a very little amount). But that does not explain why it's riding up.
2. Upper shift shaft bent due to some incident.
3. Upper motor mounts out of position which is pushing the weight of the engine on the upper shift shaft

With #2 or #3 I'm guessing that the jostling around while trailering is moving the shaft up.
or...
While shifting the upper shift shaft is grinding against the steering tube and acting like a screw and screwing itself up.

 

[Dallenx]

Re: 1988 80hp 3cyl upper shift shaft stuck UP against powerhead

Well, I tore it all down yesterday.
With the powerhead and the lower unit off I had straight access to the upper shift shaft.
It was connected to nothing but was a bear to turn and a bear to remove from its bushing.
With the bushing out and the shaft back in I was able to check the alignment between the
shaft hole in the lower cowl bracket and the hole in the lower unit. That was ok.
The upper shift shaft is straight too.
I did find that the upper motor mount has a lot of vertical play. I was checking it before for horizontal
movement (crushing) which seemed ok.
It's time for a new shaft bushing and new mounts.