84 OMC tilt 'frozen' no solutions found in search (Yes another tilt gremlin)

[Mousejockey]

I'm working on a friends boat, Tilt was 'clicking' on him and he replaced the solenoids, and it worked. Then he couldn't get the drive to go up. When trying I could hear it spinning. Disassembly of the system showed what I suspected. The roll pins for the worm gear had sheered and the shaft was spinning freely. Ordered a new shaft, pins and gasket/seal kit. Cleaned clutch pack, reassembled and the clutch wouldn't turn (clutch drive only, no worm gear/shaft). Installed a homemade thicker gasket and the clutch now spins freely(Clutch drive only, no worm gear/shaft). Now, when I install the new shaft with the nylon washer and worm gear the clutch will not move. Period. If I install the shaft only, the shaft spins free, with the worm gear no movement. I can adj the tension on the clutch pack to where it will turn, but the shaft does not, tighten the clutch and all is frozen up. Tried the worm gear alone, no shaft, and it didn't seem to want to spin, just move in/out as the clutch gear rotated.
What in the heck am I missing here??

 

[Mousejockey]

The motor seems strong, when power is applied to it (when connected in boat but not mounted) there is enough torque to spin the case, I know of no 'test' for torque but it seems good to me? Should one be able to rotate the tilt drive gear by hand/plires and have the shaft rotate?

 

[Howard Sterndrive]

did he hit something and distort the upper case, trunnions or quadrant gear maybe.... if i'm interpreting correctly it sounds like the drive quadrant is physically jamming on the spur gear.

 

[Mousejockey]

Quadrent is off, stinger held up by a jackstand. I just asked him if he hit something and he tells me he doesnt think so. I see no signs of damage to the clutch pack housing.
Simply put, as I rotate the clutch pack the worm gear will move in and out, but will not rotate, even loose on the sitting on the brass gear without the shaft.

 

[fincastle]

"as I rotate the clutch pack the worm gear will move in and out, but will not rotate" That's the point. If the worm gear rotated when pressure was applied to the clutch gear, it wouldn't hold the drive up. Only way it works is if torque is applied to the worm gear, not the other way around.

 

[Mousejockey]

Tried from the inside at the shaft with a screwdriver, nothing, not sure how much torque is req though. The shaft (motor side) appears to be flaring out now, was difficult to get past the bushing when removing (noticed this before trying by hand).

 

[Mousejockey]

Is there a way to test motor torque? Other than "feel" by holding the motor and powering it up? Seems to have good torque, not as much as a starter though.(size is relevant?)
With the roll pins sheered, I'm led to believe the motor had enough torque to do this and something from the worm gear->quadrant gear bound and the pins were the weak link.

 

[Mousejockey]

Is the Brass ring directional? Does the operation req weight/tension from the quad gear to work? Getting frustrated over this darn thing =(

 

[Mousejockey]

Looking at the new worm gear shaft this morning I noticed the roll pin holes were drilled a tad higher up the shaft, so I removed the new nylon washer from the kit, installed the shaft and from the motor side I can turn the shaft and the spur gear turns. Tonite I will install the motor and see if that nylon washer was binding up the works. There was no nylon washer on either end of the shaft (worm gear side or motor side) when I dissasembled it, nor were there any when I did mine a few years ago, how critical are these washers? Should I sand it down untill there is enough clearance?