Gearbox I f@@ked up

[Bennettrj]

whilst giving my mercury 100hp 2 stroke 4 cylinder a severe service and maintenance check i removed gearbox to replace impeller and found the water pump bolts were corroded and were gonna break off after soaking them and moving them forward and back I eventually removed all six with no problems so I replaced impeller and rebuilt water pump with no problems Then I noticed in front of water pump the gear selector had 2 bolts holding in a White nylon plate which i thought i would remove and grease bolts at the same time .......this is where it all went wrong. I removed the two nuts holding in the nylon plate I then levered the nylon plate out the casting and an o ring seal popped out and the gearbox oil ran out I lifted the nylon plug up and with it came the 6inch gear selector shaft which I now can't get to go back in far enough sits 1/2 inch high and selects no gears Any ideas how to refit it without pulling gearbox too pieces ?? Oil was in perfect condition wish I hadn't touched it now any help and advice much appreciated thanks in advance

 

[72GT160]

Wow, yeah you have issues. My guess is the cam moved a little or a lot depending on how you are working on it. If the unit has not been moved and is sitting upright in a vise or similar devise I would get a light and see if you can see down the hole and possibly use a stiff wire like a coat hanger and nudge back into place and hope the shaft will go back in the same way it came out. If it was at any kind of angle when the shaft was pulled, you have a very good possibility that the cam fell out of place. Other than that, it's disassembly time.

 

[Bennettrj]

So if I look down the hole in casting there should be a hole in the cam that the gear selector fits into if I cNt see it I need too try and rotate cam till I can see the hole ?? Correct ?? I'll give that a go today thanks

 

[72GT160]

Yes.