Bravo 1 help... hard to shift.. off boa

[Axkiker]

Hey all!!

Recently picked up a 1994 Chaparral on the cheap. I knew it had a few issues but the drive was not one I was worried about. When I purchased it I ran the motor and it shifted into forward and neutral fine. It however was a chore getting it into reverse.

So I automatically think its a shift cable binding up which is no big deal. I get the thing home and start to inspect finding that after I remove the drive from the boat the shift cable seems fine.

I then pull the back cap to check out the inside of the upper. Everything seems okay. I find that once again its really hard to shift by hand. I can do it while turning the input shaft but its tough. What I find even more strange is the input shaft seems the hardest to turn when its in neutral.

So next I pull the entire top end apart to inspect. I pull the cone clutch and gears all apart to see if something seems out of whack. Nothing seems wrong that I can see. The only thing I can see that I find odd is its pretty hard to push both gears together. I assumed it would be a fairly smooth process however it was pretty tough. Its almost like the springs inside bind up until all of a sudden they pop into place. Not sure if this is normal.

So lastly I split the top end from the bottom to eliminate the bottom being the cause (of this issue). I still have the same issue with it being extremely hard to get into gear.

Any bravo mechanics out there who can chime in.

Thanks

 

[Fun Times]

Re: Bravo 1 help... hard to shift.. off boa

The only thing I can see that I find odd is its pretty hard to push both gears together. I assumed it would be a fairly smooth process however it was pretty tough. Its almost like the springs inside bind up until all of a sudden they pop into place. Not sure if this is normal.

Hi there, Welcome to iboats!

Some of the older models before 1998 where kind of tough to push down on the gear to remove the thrust collars, keepers, thrust bearings, race and springs, cone clutch. They have since redesigned it/things a few times to make shifting/movement a bit easier.

Here's one of them, http://www.boatfix.com/merc/Bullet/97/97_18.pdf

Typically hard shifting is due to the shift detent ball & spring on the back cap will get gummed up by either dried up grease or rust due to water entering the shift cavity area.

Shifting a bravo can be a bit though to do if any of the shafts are not turning at a good clip. Also if shifted while not being turned, any of the shifting components can be bent just slightly enough so that it makes normal shifting difficult to do.

 

[Axkiker]

Re: Bravo 1 help... hard to shift.. off boa

Hi there, Welcome to iboats!

Some of the older models before 1998 where kind of tough to push down on the gear to remove the thrust collars, keepers, thrust bearings, race and springs, cone clutch. They have since redesigned it/things a few times to make shifting/movement a bit easier.

Here's one of them, http://www.boatfix.com/merc/Bullet/97/97_18.pdf

Typically hard shifting is due to the shift detent ball & spring on the back cap will get gummed up by either dried up grease or rust due to water entering the shift cavity area.

Shifting a bravo can be a bit though to do if any of the shafts are not turning at a good clip. Also if shifted while not being turned, any of the shifting components can be bent just slightly enough so that it makes normal shifting difficult to do.

Ughhhh this thing is driving me crazy... I wish I had one which I could compare how the shifting felt.

Since I have the upper separated from the lower and am having the same issue I know its the upper. At least I can eliminate half of this thing.

Any tests you can think of to diagnose or check the upper. I have all the gauges to check lash, run-out what not. Heck ive got gauges to check things I dont even know what they are. I however cant really figure out a way to check what may be wrong since I dont have a comparison. Plus you have the have the top cap etc buttoned up in order to check shifting.

 

[thumpar]

Re: Bravo 1 help... hard to shift.. off boa

My Bravo shifts about the same as my Alpha shifted minus the sound from the clutch dogs. Forward and reverse take equal pressure.

 

[Axkiker]

Re: Bravo 1 help... hard to shift.. off boa

Okay a quick update. So I noticed that the alignment marks on the gears were not totally lined up to the mark on the back of the housing. It was like this from the beginning so I assumed it was within tollerence. It was slightly off center when I got it. So I pulled the drive shaft and re-centered everything so the +/- marks all how align dead center. I re-assembled and it seems to shift with a more even pressure. Still pretty darn hard to shift by hand but non the less its more even.

After looking over the service bullitin im pretty sure that the updated cone clutch setup has not been installed. It would appear with the changes they made would allow those stupid springs to slide over the ramp easier allowing it to shift better.

I may try turning the ramp that the springs ride on down in my lathe slightly. that would appear to be a part of the fix. Worst case is it doesnt work and I get the kit.