Gears slip when engaging by hand with shift rod after resealing lower unit.

[NHStriper]

Just replaced prop shaft, driveshaft, water pump and shift cover seals on lower unit. Pressure test passed so filled with oil then tested shifting manually by pushing and pulling shift rod to engage forward and reverse gears. About 1 every 3 times I engage either forward of reverse and turn the driveshaft manually, the prop shaft doesn't turn. If I then put a little more pressure and hold the shift rod, it was engage and the prop shaft will turn, even though it doesn't seem like the shift rod moves any further up or down. Is this normal while removed from the engine and engaging manually?

Here's a list of what I removed and cleaned while opened up to replace the seals.

Propshaft Seals: Pulled bearing carrier, replaced outer needle bearing and shaft seals, pulled out thrust washer, thrust bearing, reverse gear, and mini thrust washer.

Driveshaft Seals: Pulled bearing housing, replaced shaft seals, removed/cleaned/reinstalled 2 shims, thrust washer, thrust bearing

 

[kbait]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

What motor? Do you have a model number?

 

[NHStriper]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

My bad. 1999 Johnson 200 hp J200PXEEN

 

[NHStriper]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

Tested the shifting again, this time rotating the driveshaft faster by hand while I shift. It worked better when shifting into reverse but still didn't fully engage forward a couple times, but not as bad as before.

 

[Chinewalker]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

If you're pushing/pulling randomly, then it's possible the shift dog cogs weren't aligned with the mating cogs on the gears...

 

[NHStriper]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

Pushing and pulling randomly? not sure I follow. Three setting: Up=forward, middle=neutral, down=reverse. I'm doing the same thing the shift cable would do to shift gears, but by hand. Just doesn't seem to consistently fully grab when pulling up to put in forward. Wondering if this wont happen when back on motor since driveshaft will be spinning faster and grab quicker and stronger? It's another month here up north before I can put in water to trial. Just trying to get my fix list done before the season.

 

[Chinewalker]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

The shift dog and gears will not align every time you try shifting with the motor not running. This can cause the "slipping" you've noted. What happens is the face of the lobes on the clutch hits the face on the lobes of the gear, not allowing them to engage. If the motor is running, they'll slip past that high point in an instant and allow engagement. Doing it by hand on a bench you have to be spinning the propshaft or driveshaft to get proper engagement while you're moving the shift rod..

 

[NHStriper]

Re: Gears slip when engaging by hand with shift rod after resealing lower unit.

Thanks Chinewalker! That makes sense. Glad to know it's normal. Now to the next task!