Alpha 1 shift rod connection issue

mstrud

Seaman
Joined
Dec 5, 2007
Messages
72
My old upper gears ate it. Ordered a replacement and slapped it on a spare but good lower unit I had laying around ( I didn't want to reuse the old one for fear of metal shavings hidden in it somewhere). Any how the entire outdrive is reassembled perfectly, forward is forward, neutral is neutral rev is rev. The only problem I have is when I mount it to the gimbal housing the shift connection from the housing is just barely touching the top of the upper gear case shifter. And I mean just barely touching, its not sitting inside the gimbal shifter it's sitting just below it and that's with the shift lever on the gear case hiked all the way up. they barely touch but not enough to actually shift the gear case. After pulling it apart the upper is in ship shape, cotter pin and washer are as they should be. I compared the old and new shifter connectors from the old and new upper and they're identical. I'd prefer to get this done right and not rednekin it with jb weld and a quarter inch thick inch long piece of stainless. I examined the gimble shift rod and it's up to spec. I just dunno whiskey tango foxtrot changed. Any thoughts are appreciated.
 

Cresco750

Petty Officer 2nd Class
Joined
Jul 7, 2012
Messages
192
Re: Alpha 1 shift rod connection issue

Are you referring to the intermediate shift shaft 'foot' not being fully engaged into the upper shift shaft 'shoe'? If so, then have you checked to make sure that you installed the stainless steel washer on top of the lower shift shaft seal in the lower gear case? This is there for the intermediate shaft to sit down on to set the correct height of the 'foot'. Trust me, I learned this the hard way :-(.
 

dubs283

Vice Admiral
Joined
Jul 27, 2005
Messages
5,332
Re: Alpha 1 shift rod connection issue

as stated, rubber washer over the seal and stainless washer on top of the shift shaft seal bushing - prevents shift arm from dropping down onto the seal, not engaging with the shift fork in the bell housing
 

ktbarrentine

Lieutenant
Joined
Dec 12, 2011
Messages
1,296
Re: Alpha 1 shift rod connection issue

What drive? ser #? (I'm assuming non-genII Alpha or before).

sounds like you have said that "the washer" was checked.... In any case, are you able to manually lift the intermediate shift shaft up to the point that it properly engages, or is it at max upward travel already? That would help rule out issues with the washer.
 

dubs283

Vice Admiral
Joined
Jul 27, 2005
Messages
5,332
Re: Alpha 1 shift rod connection issue

sounds like you have said that "the washer" was checked....

the washer the op was referring to is located on the shift arm in the upper, along with the cotter pin they said was there too

The problem they are having is textbook missing washer on the shift shaft bushing
 

ktbarrentine

Lieutenant
Joined
Dec 12, 2011
Messages
1,296
Re: Alpha 1 shift rod connection issue

Yep...thats why I asked about being able to lift the intermediate shift up into place. We're on the same page.
 
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