DP Outdrive not shifting into gear

[dalecover]

I have a 1996 Chris with dual Volvo Penta (OMC) 7.4GI (Model 74FFPNCA) with DP Outdrives (Model 3868443). These drives have had shifting issues since we purchased the boat 7 years ago. Immediately after purchase, we had to have the drives completely serviced and the issue was that the clutch cones were stocking and not shifting smoothly. (Turns out the previous owner hadn't had the drives serviced in a long time, and had barely used the boat for the previous 5 years or so.

That fixed the problem (for the most part), but they have always had a bit of an issue sticking in gear (hard to find neutral), which is a pain when docking the boat.

Yesterday, as I was docking the boat, the Starboard side quit shifting completely, stuck in neutral (Better than in gear when trying to dock!). Was worried that the shift cables were just way out of whack. Well, today pulled the covers off the back of the drives and verified that the shifting is happening, just not changing gears in the boat.

I've never pulled one of these apart, and am trying to determine best coarse of action. I understand the mechanics involved in the shifting process with the outdrive, so I'm wondering if the actual lever arm that moves the clutch cones may be broken.

Trying to figure what all I need. Trying to find a decent manual (When I put in the drive unit number,on the Volvo site, it gives different years, and doesn't indicate that it would be used with the 7.4s).

Any info would be greatly appreciated.

Thanks!

 

[Scott Danforth]

volvo drives are easy. pull the shift cover off and look.

when was the last time you adjusted the shift cable and linkage?

operation of the drives are all the same.

best to download factory manual, however you can view them here. Boatinfo - boat brochures and manuals for boats and marine engines!

 

[dalecover]

Thanks for the info. When I checked it out, all appeared to be operating fine (From the outside). Cables and linkage were working exactly as expected. My concern is if there's an issue with the "Shift Shoe" that moves the cone clutch. If there's been a failure inside the housing that I can't get to without disassembly of the whole gear housing.

 

[Scott Danforth]

4 bolts pulls the shift assembly. only need a new o-ring.

 

[dalecover]

Thanks again!

 

[billbayliner]

I am with Scott on this... Very easy... Actually a mechanic on Youtube replaced the seal and thus has to take the assembly apart... For a layman it was a VERY instructional video but he was a a "semi" hack in my opinion... His terminology was wrong... Calling a spring pin a roll pin and then smashing it in with a hammer and then, FUNNY, LOL, yelling F...k when he bent the pin and started hammering it the other way.... I always line it up visually and then drop a small Allen wrench in the bores to align...

My biggest issue was that he never flipped the "clevis" pin to the "virgin" side and also that he did not file down the valleys on the shift plate to get back to an original smooth, non forceful shift... Always high spots on the plates / covers... ALWAYS...

 

[kenny nunez]

If just the shaft broke off of the shift shoe it will be an easy fix.
The other thing on the AQs is the vertical shaft has a “thin spot” that will shear off just below the upper gear housing. If that happened the lower gear housing has to come apart to get to the pinion nut. Not a very hard job if you can mount the gear housing in a holding fixture.