72 ev 40hp norseman shifting

[geoffwga1]

I have this 72 40 hp Norseman that I have brought back to life and that now runs like a rolex.When I took it to the water however It kept jumping out of forward gear.Stripped out lower unit and gear case,found no undue wear,sliding dog working OK.Replaced pinion bearing 'cos it only had 13 rollers instead of the correct 16 and put it back together.went to work then on the top end and eventually got it to where the shifter lever was going through it's full travel,ie coming to rest in the detente grooves.Took it to the water today and if anything it's even worse.I can adjust up the cable until it will go into forward and stay there but will not go back into reverse and barely into neutral.I'm beginning to think something is wrong with the shifter rod itself but it is properly connected and the pinchbolt is in the notch.Please,if anyone has any ideas I would appreciate hearing them.
Geoffwga1

 

[geoffwga1]

Re: 72 ev 40hp norseman shifting

What,nobody? Come on guys someone must have come across something like this before.My sevice manual does not even mention it and the Seloc is characteristically vague I did get one or two ideas from the secret files though so perhaps someone can pinpoint something.
Geoffwga1

PS At the moment I am leaning towards the shift rod being loose at the top end.How is it connected up there.Once again my manual doesn't mention it.

 

[tx1961whaler]

Re: 72 ev 40hp norseman shifting

Does it work OK when shifting it by hand (no cable attached) ?

 

[geoffwga1]

Re: 72 ev 40hp norseman shifting

Does it work OK when shifting it by hand (no cable attached) ?

It works better but you have to hold it in gear and it still jumps occasionally.I already switched the sliding dog but I didn't switch the gears as I was not certain they were identical. I am going out to pull the lower unit again after breakfast and do some measuring of the shift rod hight.I am becoming more convinced it's to do with the top end thoguh of course I could be wrong.It looks like there is a bit of work involved in checking it out.Once again the manuals are a bit skimpy on it.
Geoffwga1

 

[geoffwga1]

Re: 72 ev 40hp norseman shifting

Pulled the lower unit again last night,checked for looseness or movement of upper shift rod.All seemed tight and OK.This motor has the 5" extension to make it a longshaft so I'm wondering could it possibly be the rod extension that is the problem.Anyone??
Geoffwga1

 

[geoffwga1]

Re: 72 ev 40hp norseman shifting

Have gone back to the bench with this and overhauled the controls and cables.Found the shifter cable was damaged under the splashwell so changed it.I thought I'd found the problem but no change on reassembly.Checked all shift rod connections,all OK.
I have torn down the gear case again and a thorough inspection has me wondering:should there be indentations on the inside(splines) of the clutch dog for the detente balls to locate in when in gear.there are none in my clutch dog and I can't see how it would stay in gear without something to hold it there.I have reversed the dog and there is very little visible wear on the corners of the ears and if it is going all the way in like it should I can't see why it would jump out.THe big question is ,"is it going all the way in and how can I find ou?"t.Any suggestions or thoughts would really be appreciated as I am stumped here.
Thanks Geoffwga1.

 

[Daviet]

Re: 72 ev 40hp norseman shifting

It's hard to tell someone how much wear on the clutch dog is acceptable, kind of a visual thing. I had a lower unit similar to yours that you would swear the clutch dog was just fine, it would not work properly until I replaced the clutch dog and forward gear. From memory, I thought the clutch dog had detents in it for the spring loaded detent balls to go into, might be wrong.

 

[geoffwga1]

Re: 72 ev 40hp norseman shifting

Thanks for the reply Daviet.I take your point about the wear issue.I would have thought there should be notches in the dog but a mechanic friend and neighbor who just brought my wifes car back says no there are none,just the spring and ball pressure should keep it in gear so I guess I'm looking at anew dog and gear.What's the mortgage situation in your area.lol.
Thanks geoffwga1