Hi there.
My problem is related to the gear box or lower end of a 2004 60hp EFI 4 stroke Mercury outboard. I purchased the boat a few months ago and noted that it was difficult to get the motor into reverse. Forward shift was ok but reverse was really tough. I have a side console open style aluminium boat with side mounted controls. My problem highlighted itself a few weeks ago when the cotrol box became stuck in reverse, luckily it was in the garage. Taking the control box apart revealed that the main control box plates (the control plate with the main lever attached and the gear linkage plate that rub together) had suashed itself to a point where the alloy plates had fractured and come away from the main body. This was caused by the pressure needed to get the motor into reverse.
So, to make a long story short, I fixed the control box with some spare parts (2nd hand parts as mercury Australia don't sell the parts separately), disconnected the rods from the motor and everything tested ok, not stiff. I then called my mechanic who came out and dropped the leg off the motor. Using his own special tool, he tried to engage reverse on the lower leg only and found that it was extremely stiff. Forward was ok, but reverse felt like something was going to break.
Taking the leg apart revealed that everythin was as it should. Nothing was busted or worn. The motor only has 130hrs on it. This motor and gearbox( not bigfoot) uses a spring to help engage the gear box into forward and the same spring is used against you to engage it to reverse ie you have to compress the spring going into reverse. My mechanic has noted that this spring seems to be my problem. Removing the spring allows free movemnet of all components. Ordering a new spring has not fixed the problem, it is the same spring. Mercury Australia have nothing to offer, they know nothing of any fault. Is this spring too tensioned for the job?
Questions . Owners, do you notice any stiffness when going to reverse on your motors? Is there a notable difference from selecting forward?
Mercury dealers, do you know of any problem? Is it supposed to be stiff to reach reverse? Could a lighter spring be used safely so that another control box is not sacrificed?
Has anyone had any similar problems when selecting reverse or have you broken any control boxes doing so?
p.s It is not the cables.
Thanks for all your help. I hope no one breaks a control box like I did because of a stiff spring loaded gear box.
cheers
Dean
Newcastle Australia.
My problem is related to the gear box or lower end of a 2004 60hp EFI 4 stroke Mercury outboard. I purchased the boat a few months ago and noted that it was difficult to get the motor into reverse. Forward shift was ok but reverse was really tough. I have a side console open style aluminium boat with side mounted controls. My problem highlighted itself a few weeks ago when the cotrol box became stuck in reverse, luckily it was in the garage. Taking the control box apart revealed that the main control box plates (the control plate with the main lever attached and the gear linkage plate that rub together) had suashed itself to a point where the alloy plates had fractured and come away from the main body. This was caused by the pressure needed to get the motor into reverse.
So, to make a long story short, I fixed the control box with some spare parts (2nd hand parts as mercury Australia don't sell the parts separately), disconnected the rods from the motor and everything tested ok, not stiff. I then called my mechanic who came out and dropped the leg off the motor. Using his own special tool, he tried to engage reverse on the lower leg only and found that it was extremely stiff. Forward was ok, but reverse felt like something was going to break.
Taking the leg apart revealed that everythin was as it should. Nothing was busted or worn. The motor only has 130hrs on it. This motor and gearbox( not bigfoot) uses a spring to help engage the gear box into forward and the same spring is used against you to engage it to reverse ie you have to compress the spring going into reverse. My mechanic has noted that this spring seems to be my problem. Removing the spring allows free movemnet of all components. Ordering a new spring has not fixed the problem, it is the same spring. Mercury Australia have nothing to offer, they know nothing of any fault. Is this spring too tensioned for the job?
Questions . Owners, do you notice any stiffness when going to reverse on your motors? Is there a notable difference from selecting forward?
Mercury dealers, do you know of any problem? Is it supposed to be stiff to reach reverse? Could a lighter spring be used safely so that another control box is not sacrificed?
Has anyone had any similar problems when selecting reverse or have you broken any control boxes doing so?
p.s It is not the cables.
Thanks for all your help. I hope no one breaks a control box like I did because of a stiff spring loaded gear box.
cheers
Dean
Newcastle Australia.
