1990 Black Max 135 Lower unit help please

[jloski]

Just replaced the impeller on counter rotating 135 mercury black max. Took off the lower unit in Fwd instead of reverse (bonehead) and when I put lower unit back on, I cannot get it to shift into gear. Prop just spins freely. I pulled lower unit off and I have the stupid Seloc manual but I can't figure out how to get the prop back engaged into gear.

Anyone got help/advice?

thanks.

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

Put a spanner on the shift shaft and turn it (gently) until it selects a gear. Turn the driveshaft in the correct direction and determine which gear you're in... Select that gear on the control box and install the lower unit....

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

spanner as in a spanner wrench?? I'm not sure what you mean to put a spanner on the shift shaft.

I'm assuming the small spindled shaft that is right behind the water pump is the shift shaft? Currently, I can raise it up and down and turn it freely in either direction up and down. I still can't get the prop to engage to the drive shaft.

can you give me some more detail, or message me if you don't feel like replying here?

Any additional input is appreciated.

THanks.

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

That small splined shaft is the shift shaft (and it's in front of the water pump, not behind it)... And it will turn quite a bit. Turn it until it reaches what feels like the end of travel, then try and turn it a bit more. In one direction it will not turn, but in the other it will continue to turn, and select neutral. You can set the control lever in the neutral position and install it...

I have an old upper shift shaft that I put a 90 degree bend in and I use that to turn the shift shaft into neutral. As I suspect you don't have an old shaft laying around I suggest you use a small adjustable spanner....

Chris.......

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

thanks for your quick reply.

Right now, the shift shaft will turn by hand in either direction without stopping. Should it be in the raised position or lowered while I'm turning? Should I be turning CW or CCW? Or is there another problem resulting in the shift shaft turning freely without stopping in either direction?

Thanks.

James

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

If you are able to lift the shift shaft more than a few millimeters, then one of the retainers has come loose... If you push the shaft down, can you spin the shaft continuously in either direction?

Chris.........
Edit: download the service manual '105140jet-135-15-175-200-225' from here...
http://rapidshare.com/files/213405838/105140jet-135-150-175-200-225.rar
Although that manual is for 1992 and up, the gear-housing section is the same for your engine.

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

right now, it raises probably about a centimenter. I can raise or lower it freely by hand. It will also turn freely in either direction raised or lowered, so yeah, if I push it down it will spin continuosly in either direction.

What's your take?

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

freaking awesome. I've been looking all over for a service manual that I could download. Thanks! Now just gotta try and figure out what the deal is with this shift shaft... any ideas?

thanks.

James

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

What's my take?

You're really not going to like the answer....

It sounds like the shaft has lifted up (due to the retainer being missing?) and the shift cam has dropped out of position. That would require the box to be opened up to relocate it... And that does require a special tool or 2.

Chris..........

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

damn... I didn't see any retainer clip on the shift shaft when I dropped the LU. In fact, I didn't even touch the shift shaft the first time I pulled the LU. I just replaced the impeller, re-greased and put the LU back on. Everything went on fine just wouldn't engage to FWD or RVS. Noticed the prop wasn't turning in either gear so I pulled it back off. What would the retainer clip look like? Something that I can replace or am I looking at a **** ton of labor/cost?

Does that manual identify which "special tools" would be needed?

thanks for all your help by the way.

James

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

The retainer I'm thinking about is like an 'E' clip that is (should be) on the shift shaft just below the shift shaft bushing. The shift shaft bushing is that screw looking part that the shift shaft goes into the gear box through.

Special tools are mentioned in the manual. They include (but not limited to) a shift shaft bushing tool and a cover nut tool.

Chris........

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

i can't open the manual. says need a password. the .rar file is encrypted. any idea what it is?

thanks.

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

i can't open the manual. says need a password. the .rar file is encrypted. any idea what it is?

thanks.

Sorry I keep forgetting about the password (silly idea anyway!)

ribforum

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

thanks got it open. You think I need to replace the whole shift shaft assembly or get it open and re-seat that cam?

thanks.

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

thanks got it open. You think I need to replace the whole shift shaft assembly or get it open and re-seat that cam?

thanks.

Re-seat the cam, probably... Depends on what you find when it's opened up...

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

Re-seat the cam, probably... Depends on what you find when it's opened up...

Finally got the shift shaft bushing off. Still nothing. E-clip is still there. No fluid issues. Pushed the shift shaft down in as far as it will go turn, turn, turn. Raise it up some, keep turning. Raise and lower it while turning, turn the prop both directions, turn the drive shaft, prop, and shift shaft all at same time. Cannot get it into any gear. WTF is the effing problem???????

ANyone please have any additional suggestions?

Thanks.

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

I'm gonna take a stab and say the shift cam is probably floating around somewhere in there? Will I need to pull the whole prop shaft and gear housing out to get to that???

Any other ideas?

Thanks.

 

[achris]

Re: 1990 Black Max 135 Lower unit help please

I'm gonna take a stab and say the shift cam is probably floating around somewhere in there?

That would be my bet too.

Will I need to pull the whole prop shaft and gear housing out to get to that???

Yep....

 

[jloski]

Re: 1990 Black Max 135 Lower unit help please

Damn. Was afraid of that. That's a little more work than I wanna get into. How the hell does the shift cam come lose? Isn't there a housing that holds it in place or a retainer clip? I'm super pissed about this. All I did was change the impeller. I didn't even touch the shift shaft aside from lining it up to the upper shaft when putting the LU back on. Everything ran fine prior to me pulling the LU. I'm stumped as to what caused this and now I'm apprehensive in pulling the other engine LU in fear of the same thing. Any theories on the cause for this dislodging??

Thanks

 

[sschefer]

Re: 1990 Black Max 135 Lower unit help please

Lift the shift shaft straight up, rotate it until you here a little tink sound. Rotate it back 180 degrees and drop it slowly, wiggling it back and forth. You should feel it stop then drop in. If your off to either side it won't drop in.

Scared the he... out of me when I did it too! Been there, done that..