Broke shift shaft coupler when installing outdrive

[JASinIL2006]

A friend called me while trying to install his Alpha One Gen 1 outdrive. The shift shaft coupler on the bell housing was not lining up with the drive shaft coupler on the outdrive. From his description, it sounded like both were oriented correctly (i.e., both the drive and boat were in forward gear), but the drive shaft coupler on the outdrive was too 'high' and was making contact with the shift shaft coupler on the bell housing. The drive was stopping and hanging up with a gap of an inch between the outdrive and the bell housing.

From what I could hear over the phone, it sounded like they were trying to crank the drive onto the mounting studs by tightening the six nuts that hold on the drive, and the drive shift coupler (on the outdrive) snapped.

I offered to help my friend repair the outdrive and reinstall it on the boat. Other than replacing the broken part on the outdrive, can you think of anything I should take a look at to make sure there isn't additional damage? Also, any idea as to how the outdrive could have been so close to being installed and these couplers weren't lining up? It seems if the drive was that close to being on the bell housing, there wouldn't be much room for those couplers to not be matched up. It is a Gen 1, though, and I'm not as familiar with them, so maybe something specific to those drives?

Thanks!

 

[RonWilder]

If he had the lower split from the upper the shift shaft could've jumped off the splines making it ride higher

 

[Fishermark]

^^ About the only thing I can think of as well... unless he doubled (or tripled) up on the stainless washer under the shift shaft. I have never heard of one sitting too high. I would suspect that they were not aligned fore and aft... despite what your friend says. That would make the most sense.

 

[JASinIL2006]

^^ About the only thing I can think of as well... unless he doubled (or tripled) up on the stainless washer under the shift shaft. I have never heard of one sitting too high. I would suspect that they were not aligned fore and aft... despite what your friend says. That would make the most sense.

Yeah, I wondered if that might be the case, too. I don't think he had split the drive over winter, and I know it went on OK last Spring (beacuse I helped him do it.).

 

[stonyloam]

I think Ron is onto it, the intermediate shift shaft was sitting on top of the lower shift shaft rather than sliding down onto it. You need a new upper shift shaft and lever and probably should update the upper shift shaft bushings and seals while you are at it.

 

[Scott06]

That's how I broke mine, wasn't lined up forced it on with the bolts. Went to start up in the spring and it wouldn't go into gear. Looked underneath saw the two halves of the linkage were jammed up, when I pulled the drive back I noticed the bronze shift shaft coupler in lower was cracked.

You have to split the drive, of course then you're in there so you're doing the water pump impeller because you're there... Make sure lower is in forward (prop held cc'w to stay in gear) when you put shift shaft coupler in facing forward, otherwise you can be a spline off. Part was expensive at the marina on a holiday weekend-$94 can find it or Sierra knock off on line much cheaper, but was in the water in a couple hours.

 

[Scott06]

Forgot to answer your question the coupler only engages in the last inch or so of the drive going onto the bell housing. There is only an inch or so of engagement in the two halves of the shift linkage. Bottom line if it takes more than a good shove to get the drive on somethings wrong.

 

[thumpar]

I agree about the upper and lower not being aligned on the shift shaft. The lower may have been in forward but the upper could be at any number of positions. Time to tear it apart and see what all is damaged.

 

[Bt Doctur]

With the engine coupler alignment good and the gimbal bearing surface rust free and the input shaft of the drive rust free you will be able
to install the drive to within an 1/8 inch simply by PUSHING IT ON BY HAND

 

[Bt Doctur]

With the engine coupler alignment good and the gimbal bearing surface rust free and the input shaft of the drive rust free and having the shift in fwd and the drive in fwd you will be able to install the drive to within an 1/8 inch simply by PUSHING IT ON BY HAND

 

[JASinIL2006]

I know, I've learned not to force it... unfortunately, I was a few miles away and just heard what happened over the phone. I'm going to go over this weekend and see if I can help him get it on correctly. After we fix the shift shaft coupler...