Alpha Clunking in Reverse - Cable, Clutcth, Gears?

[Sea Gullible]

I have an Alpha 1, 350 Merc, 22 ft boat.<br /><br />When I put her in reverse, the outdrive thumps repeatedly and firmly as if it is not all the way in gear. She does move in reverse so the prop is turning. <br /><br />When I do shift into reverse, I swear it pops in as it sounds similar to the forward shift which works fine. If I am not in the water, running from hose, the thumbing is not as serious but I can still feel it vibrating the boat.<br /><br />It was doing this before and after I put in a new lower shift cable. I understand I may need some practice and experience to properly adjust the cable but wondered what else this issue could be in case a proper adjustment didnt work. Clutch dog, reverse gear, etc?<br /><br />Thanks!<br /><br />SG

 

[Don S]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

What manual are you using for adjusting the linkage?<br />Is it a Alpha I or an Alpha I Gen II (What year?)

 

[Sea Gullible]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Hi Don,<br /><br />89 Alpha 1<br /><br />I have been using the directions on mercstuff.com<br /><br /> http://www.mercstuff.com/images/shiftcable.jpg <br /><br />and the Seloc manual. <br /><br />SG

 

[Don S]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Below is a link to the MERCRUISER OEM service manual. Section 2A tells you EXACTLY how to adjust your particular model.<br /><br /> http://www.boatfix.com/merc/Servmanl/6/6covr3.pdf <br /><br />You could also have a bad cable between the throttle/shift control and the engine. If it is worn internally and has too much slop in it, it won't allow full adjustment in both directions no matter how much you adjust it. Replacement is the only option.

 

[Sea Gullible]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

So you dont think it is an issue with the clutch dog being worn or similar issue?<br /><br />SG

 

[muc]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Might want to start with shift system troubleshooting on page 1C-38 before you start adjusting anything. Sure it could be a worn clutch dog/gear set, but it is sometimes best to start with the least expensive/easiest things before jumping to the most expensive/hardest things. Good Luck, Muc

 

[KRS]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Don, could it be the interrupt switch causing the problem also, I remember you helped me with mine a year or so ago. Mine was difficult to get into reverse, and that turned out to be the problem.

 

[Sea Gullible]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

is there a different link to the full section of the above manual or is that just a guide for which one to buy.<br /><br />Cant seem to find it on boatfix.<br /><br />Thanks all, appreciate the help.

 

[Don S]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Sea Gullible just run your cursor over the cover page where it says Sterndrive unit inside the red box. Then click it will give you the index page.<br />Then as you run your cursor over the different sections you will see it change. Each section opens seperatly. I would also check the cables and adjustment before I went to tearing the drive apart. <br /><br />Azf, no, the shift interrupt switch will not cause it to jump in and out of gear.

 

[Sea Gullible]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

got it!<br /><br />Oh trust me, the last thing I want to do is open the lower end, just wanted to get an idea of what the worst case scenario would be.<br /><br />Thanks again for the help

 

[Sea Gullible]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Hi Guys,<br /><br />Well, I am pretty sure it is not the cables as I replaced them both and the issue still exists.<br /><br />I assume now it is a bad clutch dog or chipped reverse gear. <br /><br />I am now ready to replace the worn parts or replace the lower end with one from gear-case.com<br />I dont think paying my local mechanic 1500 bucks to do it makes sense when I can get a rebuild for 850 with a 1 year warranty. I can keep the core and dismantle it with my "spare" time.<br /><br /> http://www.gear-case.com/gear-case-pages/Alpha-One-Lower.htm <br /><br />Has anyone done a rebuild or used a case from gear-case.com<br /><br />Would a rebuild require all new parts or just those damaged.<br /><br />Thanks for your help as usual.<br /><br />Gull

 

[qystan]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Take a look at the oil drain plug. If there's something wrong in the gearcase, you can expect to see metal chips.<br /><br />Rebuild is not difficult, but you'll need the manual (use the Merc original), special tools, especially for the shimming and a hammer puller to get bearings off. The tools will cost.

 

[DHPMARINE]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

You might also look at www.sterndrive.cc .Also what does Iboats offer.I just priced a gear set,seal kit,clutch dog and water pump (impeller only) and came up with $850.00.Parts only.<br /><br />DHP

 

[Sea Gullible]

Re: Alpha Clunking in Reverse - Cable, Clutcth, Gears?

Funny thing is, when I drained the oil, there was minimal metal on the magnet. I suspect this issue has been around for a long time before I bought the boat so it was just something the previous ownder ignored. Like I said, I had a dishonest guy do the survey and he didnt inform me of any drive issues.<br /><br />That said, when I did the pricing on all the tools, parts and labor (me) it came out over 850. I can get a new aftermarket for 695 on ebay including shipping and 1 year warranty and I can keep my core, sell it or take my time rebuilding it I guess. Hell, for 695 I dont see a huge downside unless it blows while out in the islands. Most folks seem to have had decent experiences with these things.<br /><br />I have been battling this issue for months now between work and waiting for parts etc so I just want to get her in the water!<br /><br />Thanks for the feedback guys.<br /><br />Gull