60hp Gearbox Problem

[NZ-Kevin]

Hi,

Sorry this is a bit long winded, but I need to explain the circumstances of the gearbox failure as I think I caused it with a mistake Imade. The engine is a 1971 60hp (60es71c).

We went out fishing and when we stopped to anchor I climbed out to put the anchor down like I usually do. I always leave the engine running until safely anchored, but it must have stalled while I was sorting out the anchor and when I climbed back into the boat I just thought my wife had turned it off. So the key was left turned on while we were fisahing foe several hours. I only noticed when we came to leave, and the battery was completely flat by then. I connected the spare battery and started the engine, but there was no forward gear. It just stayed in neutral when forward gear was selected. Reverse worked, and it went back into neutral -but wouldn't go into forward. When we got the boat out of the water (after being towed back by the coastguard) I turned the prop and it span freely when the engine was off and the ignition was off, so not in forward gear as it should have been.

I thought about it and think this is what has happened, but hope someone who knows more than me will either confirm this or give the correct explanation. Leaving the ignition on would have kept the solenoid activated to engage neutral, which is whythe battery went flat. I'm thinking that being held in neutral for such a long time must have weakened the spring that pushes the gears into forward gear. The natural state ofthe gearbox is now neutral instead of forward. So I'll need to strip the gearbox and replace the spring. DOes this sound reasonable, or could there be another reason for this?

I'm also plannin gto fit a bright LED warning light on the dashboard connected to a circuit that is swiched on with the ignition, so I shouldn't do this again!

Thanks
kevin

 

[filth]

Re: 60hp Gearbox Problem

I have an 88 HP that I have left idleing in neutral for long periods of time. Sometimes it would die due to Carb problems but when restarted it ran fine. I can't imagine how a few hours of fishing would be enough to kill your battery unless your running a lot of electronics. You may have a bad foot but its probably not your fault.

 

[wilde1j]

Re: 60hp Gearbox Problem

It's electric shift.

 

[F_R]

Re: 60hp Gearbox Problem

Kevin, that is a nice theory you have, but it just isn't valid. There is no way you weakened that spring.

If it is in neutral when not running, there can be only one cause: The clutch dog piston is stuck in the oil pump bore. It happens from dirty oil. Unfortunatly, there is only one way to fix it, which is tear it apart. Once that fine grit is imbedded in the soft aluminum pump bore, it isn't coming out till you get in there and manually remove it. The oil pump is the last thing to come out of the case and the first thing to go back in.

 

[NZ-Kevin]

Re: 60hp Gearbox Problem

Kevin, that is a nice theory you have, but it just isn't valid. There is no way you weakened that spring.

If it is in neutral when not running, there can be only one cause: The clutch dog piston is stuck in the oil pump bore. It happens from dirty oil. Unfortunatly, there is only one way to fix it, which is tear it apart. Once that fine grit is imbedded in the soft aluminum pump bore, it isn't coming out till you get in there and manually remove it. The oil pump is the last thing to come out of the case and the first thing to go back in.

Yes, I had been thinking more about it and decided something must be stuck, but whatever the problem is I do know that leaving it in neutral was the cause -as it was fine up till that point. Too much of a coincidence. As for running the battery down quickly, it probably isn't the best battery in the world anyway as if left stood for a month it needs re-charging before use -probably time for a new one.

 

[F_R]

Re: 60hp Gearbox Problem

No, putting it in neutral caused it to stick. You just got lucky (?) that it happened at that particular time. Well, OK I will concede that leaving it running in neutral for a long time may have contributed to it. When it is running in neutral, oil is under pressure against that piston. There is a slight leakage going by the piston because it has no "rings" or seals. So, over an extended period of time, considerable oil has passed through the leakage path, taking considerable grit with it. Remember, it is the grit that caused it to stick. But still, the bottom line is it was going to happen anyway. Hey, been there, done that, fixed that----on several of them.

 

[NZ-Kevin]

Re: 60hp Gearbox Problem

I'll let you know what I find when it's stripped, which may not be for a little while. Popped in to the local Johnson/Evinrude dealer today for some advice, but it seems that even I know much more about these engines than they do, quote "you're on your own with that one, anyone who worked on those is either retired or dead"

 

[F_R]

Re: 60hp Gearbox Problem

Well he got that right. I'm retired. 24 years as an Evinrude dealer mechanic. But not dead.

 

[EN2]

Re: 60hp Gearbox Problem

Hey, F.R. its a good thing your not.

 

[NZ-Kevin]

Re: 60hp Gearbox Problem

Glad to hear that F_R. Stripped it down, shaft/spring/clutch assembly OK, pump was pretty mucky. I'm soaking the filter overnight and will give a good clean tomorow. Will also strip and clean the pump & piston, then maybe it will work when it all goes back together. Was pleasently surprised the pump pulled out fairly easily as it has probably never been out before.

 

[F_R]

Re: 60hp Gearbox Problem

My hat's off to you, you are more talented than the average bear. Good luck with it.

Btw, it is important that the piston slide freely in the pump bore, but do not make the bore oversize while you are cleaning it up. You will cause excessive blowby if you do.

 

[boobie]

Re: 60hp Gearbox Problem

Don't forget the oring that goes around the plunger in the pump hsg. Part# 314491

 

[NZ-Kevin]

Re: 60hp Gearbox Problem

Yes, I'm planning to replace that on rebuild. I'm still cleaning the filter as it isn't available as a spare here. I've got it in my little ultrasonic cleaner and it's gradually coming clean, but it might take a while.

 

[NZ-Kevin]

Re: 60hp Gearbox Problem

Well, good news and bad news. Fixed it all and put it back togehter and it went well, up till a few days ago. Travelling back from a days fishing and a very loud bang followed by screaming engine and no drive. Killed the engine and had to get a tow back. Got the boat out of the water and discovered that some gear parts had decided to exit the gearbox, through the casing and go for a swim. It hink even I'll have to admit defeat on this one now. Have bought a secondhand 1970 60hp, with dud ignition. Will fit that and canibilise any parts needed from my old engine. Expect posts soon on ignition problems!