Adjust shift cable without pulling off my lower unit? UPDATE-part name and method?

[projo198]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I'm trying to remember... but on my old lower shift cable there was an extra flange on the end of the cable housing that wasn't on the new one. Or vice-versa. I can't remember now but I may have taken a pic... Maybe that is the difference.


I didn't think much of it but it seemed odd to me at the time.

 

[Reinell-BRXL-191]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I am assuming it is with a purchased jig.

My manual also states 7 9/16" but its a manual from the early 90s.

Right, and so is mine... and that dimension is "post-failure" - the 5/8th dimension is "pre-failure" and I think everyone should drop that dimension because it is confusing people making home made jigs.. and everyday I see someone telling people to go to Hasting's site.. where they are viewing the same document MRS posted.. and it has the bad dimension on it from a earlier 80's manual - This can be verified by the lack of any "critical" warning and the lack of the tool being mentioned

 

[Idlespeedonly]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

The 7-5/8" dimension is critical to a point. The main purpose is so the black plastic piece does not bottom out on the casing guide when you shift into reverse. This is why the 4 15/16 dimension they give you on step 9 is also important. When you adjust the trunion barrel you are basically making the dimension useless. Another reason they specify the dimension is so people dont have all kinds a varying lengths. The main thing is the bellcrank setting and all the pushing and pulling you do in the last few steps.

 

[Reinell-BRXL-191]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

If you follow the directions, and set the 7-9/16th (NOT 7-5/8th) and then set your bellcrank to 90 degrees (hopefully with the proper tools or measuring devices) then screw down your drive side cable and tighten it.. there is no way that moving the trunion barrel will change that dimension.. the trunion barrel is designed to move the entire casing and core to center neutral with the main shift cable to shifter. It can effect how far the shifter actually moves the bell crank, but it does not ever change the critical dimensions that the tools create, these dimensions are for the inner shift cable core. The truinion barrel moves the outer casing or entire cable position if you will...

 

[Idlespeedonly]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

Think about this for a minute, If your 7-9/16" dimension was set at 7 13/16(.250 longer). Then move the trunion barrel .250 in the same direction. You geometry wise havent changed a thing. The bellcrank at 90 degrees is extremely critical. So as to make sure you have equal movement in both directions.

 

[Reinell-BRXL-191]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

That logic only works with a loose drive side cable.. and there should not be any barrel trunion adjustments going on until both ends of these dimensions are locked in place...

Ok... here we go... the 7-9/16th dimension is set on the cable length tool, then you go set the bellcrank to 90 degrees with the alignment tool. You then screw down the cable guide nut and then lock it in position with the guide bolt- this in fact locks the inner cable to the first dimension of 7-9/16th - the only way to change that dimension is to move the bellcrank up or down. But in all reality, you are just moving the dimension from one end of the cable to the other... you can screw the trunion barrel all the way to either side - it will not change the inner cable dimension - once the inner cable is locked at the proper dimension, moving the barrel only moves the entire cable, I understand what you are getting at... but maybe we are just disagreeing about how it is being said.. because you are assuming the added connection of the shift cable to the lever arm, and that by moving the barrel, it is pushing the cable in or out against that lever arm pin.. but.. it is still not changing the dimensions of the cable length, it is only transferring the dimension from the cable side to the bellcrank side.. the inner core of the cable remains the same... that's why these dimensions are done with all cables removed from the engine and drive sides

Ok. now we are probably over complicating a good thread with good info in it... we should stop..

 

[MRS]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I am assuming it is with a purchased jig.

My manual also states 7 9/16" but its a manual from the early 90s.

Mine also said 7 9/16 cobra manual and the jig was purchased not home made. When cable was done in the jig it also did come out to 7 5/8 but it worked well for me no extra adjustment needed after connected and the throw was perfect each way. OK just letting you guys know what I did and how it worked out. Not trying to change anybodys mind or say there wrong I am done here good luck with your repairs. Took about 1hr. total with the two bought tools by myself...

 

[Idlespeedonly]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

That logic only works with a loose drive side cable.. and there should not be any barrel trunion adjustments going on until both ends of these dimensions are locked in place...

Ok... here we go... the 7-9/16th dimension is set on the cable length tool, then you go set the bellcrank to 90 degrees with the alignment tool. You then screw down the cable guide nut and then lock it in position with the guide bolt- this in fact locks the inner cable to the first dimension of 7-9/16th - the only way to change that dimension is to move the bellcrank up or down. But in all reality, you are just moving the dimension from one end of the cable to the other... you can screw the trunion barrel all the way to either side - it will not change the inner cable dimension - once the inner cable is locked at the proper dimension, moving the barrel only moves the entire cable, I understand what you are getting at... but maybe we are just disagreeing about how it is being said.. because you are assuming the added connection of the shift cable to the lever arm, and that by moving the barrel, it is pushing the cable in or out against that lever arm pin.. but.. it is still not changing the dimensions of the cable length, it is only transferring the dimension from the cable side to the bellcrank side.. the inner core of the cable remains the same... that's why these dimensions are done with all cables removed from the engine and drive sides

Ok. now we are probably over complicating a good thread with good info in it... we should stop..

I think we are agreeing, just saying it differently. BTW, Those tools you made look really good.

 

[Boats-A-lots]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I'm confused.. (and I will be doing this in a day or two). What is the correct measurement between A in this pic? Is it 7 9/16 ?

 

[LAC_STS]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

That's what I was wondering. I supposedly have an original 1989 OEM OMC manual and mine says 7 9/16

 

[bruceb58]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I'm confused.. (and I will be doing this in a day or two). What is the correct measurement between A in this pic? Is it 7 9/16 ?

I believe that is correct and it really doesn't matter if you use this tool and the bellcrank tool. If you aren't using the bellcrank tool, you have already lost any of the accuracy that you need for this measurement.

 

[Boats-A-lots]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I believe that is correct and it really doesn't matter if you use this tool and the bellcrank tool. If you aren't using the bellcrank tool, you have already lost any of the accuracy that you need for this measurement.

Thank you Bruce. In about 10 more years if I lose the ability to make a square angle, I will buy that tool. I have done years and years of math, angles, building, designing and construction to not be able to figure out how to make that little thing (bellcrank) sit at 90 degrees. I do appreciate the efficiency expert who thought up these tools though. (figured it would have to be some one who was saving time money and man hours on this shifting system.

 

[bruceb58]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I do appreciate the efficiency expert who thought up these tools though. (figured it would have to be some one who was saving time money and man hours on this shifting system.

Unfortunately for OMC, they came out with the tool after spending millions of dollars replacing gearsets for customers under recall. The older manuals specified using the 90? straitedge and the newer manuals specified using the newer tool. Even the dealers they had trained to install the shift cables with the straightedge weren't able to do it that way and that is why they came up with the tool.

I have replaced 3 of these cables and wouldn't even consider doing it without the tool.

 

[Boats-A-lots]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

Uh huh and I know first hand (and can imagine) how shops were setting that bellcrank. Instead of taking their time it's how fast can I get this done and out the door. If you take your time there isn't any reason in the world why some one couldn't get that bellcrank at a 90 with out that tool. They were more trying to idiot proof what shops were doing or rather make sure they didn't have to spend more then 10 mins setting the crank and cable.

Shops charge outrageous rates and claim they have to keep up with the latest and greatest tools and electronics to fix our autos and boats. Those new tools, training and gadgets are expensive, so the buck gets passed to Joe customer. It isn't a matter of lets fix this boat right, it's how fast can we fix this boat and move on to the next. If that tool saved a shop 10 mins per boat, times how many boats in a season, well.. that's a lot of get it done and out the door time. OMC's standing would have been to a shop replacing gears "did you use that tool setting the bellcrank"? If you didn't they wouldn't cover the cost the shop would.. or rather Joe customer would.

The lack of that tool wasn't OMC's downfall. Bad design.. maybe, weak cables, shops that didn't care, poor upper management the FICHT fuel injected motors and many other issues.

 

[LAC_STS]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

I installed a new transom bracket shift cable and adjusted it myself using the straigtedge way. But I just ordered a set of the plastic tools for $55 with free shipping on eBay.

To me its worth the piece of mind. If my Cobra drive were to go I would be in a very bad situation and most likely end up having to replace it with a used one that I would hope would be good and last.

$55 is nothing compared with the cost of a drive which no body wants to work on anymore, there are no new replacements available, and real reman ones going for 3K online.

When I sell my boat and dont have an OMC anymore I will sell my tools and recoup some money. Maybe in the long run Ill only end up paying $25 for it.

 

[bruceb58]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

The purpose of this forum is for people to share their ideas and the best ways to solve the problems from people who have already done this work over time. Obviously its up to you to do it anyway you want to do it. Anyone who reads this thread later can decide for himself if he wants to do it the recommended way that the factory specified in its service manual or not.

I always prefer to spend money on tools to make my job easier and with better quality. As an engineer, that is what I do at my work and that translates to what I do when I work on my boat, car and home.

 

[LAC_STS]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

The purpose of this forum is for people to share their ideas and the best ways to solve the problems from people who have already done this work over time. Obviously its up to you to do it anyway you want to do it. Anyone who reads this thread later can decide for himself if he wants to do it the recommended way that the factory specified in its service manual or not.

I always prefer to spend money on tools to make my job easier and with better quality. As an engineer, that is what I do at my work and that translates to what I do when I work on my boat, car and home.

+1

Me too. I buy a tool anytime it will make something easier.

 

[Boats-A-lots]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

My wife is an engineer for the state of Oregon (highway bridge construction). I'm a house builder. When she came out to check on my progress and I showed her what I was doing and explained there is a special tool to hold this (pointed at the bellcrank) she said "uh huh, and if you can't do that with a square, or protractor, I want a refund on the house you built.

I know what your saying... and I may buy the tools for the 55 bucks, and add to my collection of things I may or may not use. Everyone has a comfort zone of what they do. I wouldn't attempt to do my dental work, or take a engine apart, but this bellcrank angle is right in my zone.

 

[Idlespeedonly]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

$55 is nothing compared with the cost of a drive which no body wants to work on anymore, there are no new replacements available, and real reman ones going for 3K online.

Everybody keeps forgetting about the SEI option.

 

[Boats-A-lots]

Re: Adjust shift cable without pulling off my lower unit? UPDATE-part name and method

Everybody keeps forgetting about the SEI option.

Hey Idlespeedonly, What is the SEI option? Is there a thread that explains it?