Installing Shift Cable

[RC54]

1983 Mercruiser 260 Alpha One.

When I pulled out my old lower shift cable inner core I felt some resistance at first but it finally gave way and slid out. I just thought it was tight going through some bends. I decided that the old cable was still in good shape and I could reuse it but when I pushed the inner core back in it pushed out a very small stainless tube, out the upper end where it connects with the upper shift cable. Looking at this small tube it appears that it had been crimped onto something on one end. I cannot get it to slide back onto the inner core at all.

I did buy a new cable kit that I was just going to save for now, and in that kit there is the same small stainless steel tube, but it is open on both ends, so that it can slide freely on the inner core. I can find nothing on youtube or any forums that discusses this tube and what to do with it. I'm not even sure where it goes. Pretty sure it will have to go on one end...either the upper end or the lower end, where it slides into the fork. But, is it supposed to be crimped somehow?

Not sure at all what to do with this and I'd really like some help or advice.

 

[Bt Doctur]

Being a `83 you should not be cutting and measuring the cable core, you should have updated to the newest style shift cable. What the number of the kit you bought?
When installing the old style you needed to measure and cut the cable and slide the sleeve on the control side and crimp with diagonal pliers. The new type cable eliminates all that nonsense.

 

[RC54]

I wasn't cutting and measuring anything. I was simply trying to put my old core back into the shift cable that I had removed it from before, so that I could remove the bell housing to replace the bellows, when this tiny tube came out of the end. I didn't see where it had come from so I'm not sure what to do with it. Could it be that my old one was one of the old style?

When you say "control side" are you referring to the side in the engine compartment?

The new kit I bought was Sierra 18-2600.

Thank you for addressing my problem.

 

[Bt Doctur]

that is a front entry type,(old style) ,the SS tube goes on the end inside the boat . Leave about 3/8the of the cable sticking outside the sleeve and crimp it with diag pliers.install the black plastic sleeve and adjust the cable
Should have used 18-2603

 

[Bt Doctur]

 

[RC54]

Here's a couple photos of my original cable, aft side and front side of bell housing. Is this the old style cable? Hard to believe that it's been in there all these years without any problems.

 

[Bt Doctur]

the pic indicates a new type that does not use the inner sleeve .A poor analogy but the old type was like garage door cable and the new type is more like speedometer cable. The cable the would enter the housing from the front is okd type, the cable that enters from the rear is the new type.
Insert the core ,it must enter fully with "no resistance" .If it does its should still be good and install everything but the sleeve on your old core.
somebody may have tried to reuse a old core in a new cable sheath

 

[Bt Doctur]

this will explain it better
http://www.boatfix.com/merc/Bullet/83/83_27.pdf

 

[RC54]

Thanks Doc. Now I'm really concerned as there was quite a bit of resistance at first when installing the core, I think I will just bite the bullet and buy a new style and replace the entire cable. I've already installed the bell housing. Will I be able to replace it without removing the bell housing again? Seems like it.

Thank you very much for taking the time to help. I've been a corporate jet mech for 40 years now so I know my way around mechanicing. Seems like boats are a lot like airplanes...everything you do is really expensive!

 

[Bt Doctur]

You can but first get a old "control cable" from a shop and get the solid core to use as a guide because on some boats its impossible to see how to route the cable

Check your messages

 

[RC54]

Is the18-2190 kit the same cable, without all of the other stuff that I don't really need? I already have all of the other components that are included in the 18-2603 kit, so I don't see the need to purchase them again. Not sure it would be the correct length. Doesn't specify.

Thanks...Randy

 

[Bt Doctur]

With the example I said about the description of the inner cable what type do you have?

 

[RC54]

OK, bought the 18-2190 kit and removed my old cable. It did unscrew from the aft side so that was a relief that I didn't have to buy the special tap to tap out the hole to accommodate the new style cable. I guess someone at some point put in the new style cable but installed the old style core as the core that I removed was definitely the stranded wire type core. Nothing like the new one. But, they did install the support tube that's needed with the old style core.

Anyway, got the new one installed yesterday and installed the drive today and adjusted the shift, and all is good!

Kudos to you Doc for your expert help! Your recommendations and advice made the job much easier for me.