lower shift cable replacement

[Exotic4x4]

Ok guys never replaced a lower shift cable before,mine had some issues going into forward gear but always went into gear when I physically jiggled the cable shift interupt shift it working correctly, ?????? Is in my mercruiser book and original mercruiser maintenance book I got with my 89 Larson both show how to adjust and replace,it also refers to 2 different specialty tools I need, A; do I need these tools and B; is it as big of a pain in the butt to replace as the books show? Anyone know of a good sticky on a step by step on here? Manuals seem to make it look harder than it is,I hate reading then having to refer to a figure in the manual....also while inspecting the last time out I noticed the cotter pin on the shift barrel wasn't there....not sure if it vibrated out or what but I noticed it wasn't there and that was an issue I fixed as soon as it was home.but want to replace the lower shift cable just to be safe . Or should I spend the 250$ and have the local marine shop install it...Daaaah!

 

[CharlieB]

Re: lower shift cable replacement

If you can pull the outdrive off, you can change the lower cable.

There are two different lower cables depending which one your transom uses. One screws into the drive hood from the outdrive side, the other screws into the hood from the transom side.

Once the drive is off you can clean out the accumulated grease and see the end of the cable housing inside, if you see the 'nut' your cable installs from the drive side, the extra long deep socket (6 point) is very highly recommended.

If your drive uses the other cable it is often easier to pull the pivot pins and bellows to use a 'flare' wrench.

 

[Exotic4x4]

Re: lower shift cable replacement

I think pulling the.drive.is the.easy part, my merc book makes it sour complex

 

[fishrdan]

Re: lower shift cable replacement

The extra deep socket can be made, just weld a tube and handle onto a deep 6pt socket, or weld 2 deep sockets together. The crimp pliers can be made too, by welding a nut onto pliers, drill out the nut, then cutting the nut in half. I made both, not hard at all if you have a welder.

I wouldn't be too intimidated by the lower shift cable replacement,,, if you are mechanically inclined. Though, I would look at the bellows before doing the job and replace them if needed. If it's been 5 years since the bellows were replaced, just replace them. Also check the gimble bearing and Ujoints to see if they need to be replaced while you in there.

If you have the correct Mercruiser manual, follow that as it will be better than a post you dig up here, nothing missing.....

 

[Exotic4x4]

Re: lower shift cable replacement

Well im a machinist I can make the tools if its really that easy maybe make a complete set of pliers using mastercam lol ill look when I get home and let u al know the manual I have

 

[Exotic4x4]

Re: lower shift cable replacement

I have to clymer mercruiser sterndrive shop manual it covers 1986-1994 alpha one,bravo one bravo two and bravo three its 627 pages long good manual??

 

[achris]

Re: lower shift cable replacement

I have to clymer mercruiser sterndrive shop manual it covers 1986-1994 alpha one,bravo one bravo two and bravo three its 627 pages long good manual??

Sorry, nope... Good for toilet paper, or hand wipes, but as a service manual? Leave a lot of stuff out, and most other stuff is just plain wrong....

What drive do you have and I'll post up a link to the genuine manual... (serial number would be the most useful)...

Chris........

Edit: Most likely an Alpha style, so here is the manual for R, MR and Alpha One drives (1983-1990) -> http://www.4shared.com/document/zz_5pj9o/Service_Manual_06.html

 

[Pete104]

Re: lower shift cable replacement

CLYMER sucks!
You can go spend the $250. But what if it don't fix what your chasing?

Where @ in Wis.?

 

[achris]

Re: lower shift cable replacement

CLYMER sucks!
You can go spend the $250. But what if it don't fix what your chasing?

Where @ in Wis.?

Where do you get $250 from? Even from Merc themselves the manual is only about $80, and from eBay you could get one for about $30-$40.... or click my link and download if for gratis...

Chris........

 

[fishrdan]

Re: lower shift cable replacement

Or should I spend the 250$ and have the local marine shop install it...

You can go spend the $250. But what if it don't fix what your chasing?

Where do you get $250 from?

Right,,,, there...

 

[Bondo]

Re: lower shift cable replacement

Well im a machinist I can make the tools if its really that easy maybe make a complete set of pliers using mastercam lol ill look when I get home and let u al know the manual I have

Ayuh,.... I was afeared the 1st time I did it,...
I avoided it for the longest time...
I'd decided to do ALL the rubber parts at the same time....
I'd gone, 'n made the Special socket, 'n all...
Finally, I said to 'ell with it, 'n started rippin'...

Followin' the Factory manual(see achris's link), it went Perfectly...
I didn't even need the socket, as the new Merc cables you can just spin the offending nub of plastic out, install the cable, then screw it back in...
The hinge pins, I used an allen wrench for...
All in all, it was just over an hours job, even for a virgin installer...
With NO Special toolage...

Btw,... Don talked me into goin' with the factory Merc cable, 'n I used the sierra parts for the rest of the job...

Yer a Machinist, you understand how things fit together,...
Go ahead, 'n Dive in, it ain't so bad....

 

[Don S]

Re: lower shift cable replacement

Here are links to download the engine and drive manuals for your 89 Larson

Engine http://www.4shared.com/document/hh5Z9V47/Service_Manual_10.html
Drive http://www.4shared.com/document/zz_5pj9o/Service_Manual_06.html

To remove the drive. Put shifter in forward gear, disconnect trim rams from the outdrive, remove 6 nuts that hold the drive to the bellhousing, pull outdrive off.

Section 4A of the drive manual covers replacing the shift cable. Section 2 covers removal and install of the drive, along with cable adjustment.

You will need an alignment bar if you plan on working on your own engine and drive. It's a must have. Since you are a machinist, there is even a drawing up in the adults only sticky so you can make it yourself. http://forums.iboats.com/showthread.php?t=329915

Lots of first timers have installed their own cables and bellows, and there is also plenty of help from the forum if you get stuck.

 

[Exotic4x4]

Re: lower shift cable replacement

Well that's good to know guys, clymers show a different set up for my barrel, my barrel sits in a cup with a cotterpin, that's why I was kind of freaking out.I have the factory book that the dealer would use to install the drive and shift cables its about 30 pages long, ill plan on using that and the links on here and just pull up my skirt and just DO IT. Yall are very helpful and willing to share your knowledge also PETE104 I'm in Western Wisconsin.

 

[achris]

Re: lower shift cable replacement

Right,,,, there...

It came right after the reference to the clymer book. I just assumed here was referring to the price of a Merc manual... Sorry, my bad....

 

[achris]

Re: lower shift cable replacement

... just pull up my skirt and just DO IT. ....

We've all played that game...