Mercury/Tracker 60hp Shift Shaft Issue

[AmericanHoney]

This last weekend I decided to change both the impeller and seals on my lower unit. It was my first time attempting it and things went well enough until I came to the shift shaft seal. Changing the seal went fine, but when I replaced the shaft I noticed that it spun 360 degrees freely, where as before it didn't move. After doing a little researching I came up with that I must of moved the lower unit enough that the shift cam moved out of position. Sh I tipped it around a bit and was able to move the cam back so I could insert the shift shaft back into the keyways.

But noticed that the shift still moved, something still didn't appear right. It now spins about 220 degrees freely and hits solid stops on each end. The prop ratcheted CW and would turn CCW so I thought maybe it was just in gear and reattached the lower unit with the shifter in forward. But it remained stuck in that gear and could not get it to change not matter what location the shifter was in.

I researched a bit more and read about turning the shift shaft while possibly moving the prop to cycle through the 3 gears, then once it was in a known gear reinstall with shifter on correct gear. That seemed easy enough but my problem lies in the fact that I can't get it change gears turning the shift shaft. It just spins freely and hits the solid stops on each end of rotation. I put an 11/32" socket over the spline and tried turning it using a bit more leverage but it doesn't move and I am afraid of doing even more damage.

I am at the point that I am planning on taking it into a shop to figure it out, but I thought I would ask on here just in case there was a quick and easy solution to my stupidity. Any advice, guidance, tips, or things to try would be greatly appreciated. thanks in advance.


Engine is a 60hp Tracker Pro Series Serial # 1B048511.

Thanks.

 

[AmericanHoney]

Anybody got a guess? Do I just need to turn it harder or is there something else most likely messed up?

 

[Guest]

I have the EXACT same problem, same motor too! I had to take mine to the shop as well, the shift shaft just spins. I actually made a video of it here:

https://www.youtube.com/watch?v=_lglBC_5K8A

I think the only way to fix it is to pull everything out, bearing housing on the prop shaft, gears, etc. to get to the cam or clip that keeps the shift rod on. I haven't heard back from the shop yet but you mind as well have them do the prop shaft seals while they have it apart.

I've heard that lifting the shift shaft is what messes up the the cam or clip, but I don't know for sure.

Basically, we're both screwed. Probably gonna cost me close to $250 to fix at the shop.

 

[AmericanHoney]

Actually your video shows what my shift shaft was doing when it wasn't in the shift cam down in the lower unit. it would spin 360 degrees like that. I pulled the shift shaft out again and the jostled the lower unit around looking down the shift shaft hole until I saw the shift cam move back into position with its female spline centered. I was then able to put the shift shaft back in. Now my shift shaft won't spin 360 degrees it is just about 200 degrees with hard stops on each end (cw/ccw). From what I have read and even spoke to a mechanic over the phone I am suppose to now turn the shift shaft CCW and rotate the prop at the same time to get it to snap into the 3 different gears. Once I get it into a known gear I match that on the shifter and reinstall the lower unit.

My issue is that when I turn that shift shaft CCW it comes to a HARD stop, I've put an 11/32" socket over the spline and tried turning it with some force while turning the prop but it will not click into gear. I am afraid of pushing too hard and snapping the shaft. From what I read it shouldn't take a lot of force, so I am afraid there is something else is wrong. Have been many people with the same problem that were able to solve it using the steps I mention above, so I just don't know what my issue is. Forced to have to take it in myself.

 

[Guest]

Oh wow, so you're saying that I could have fixed the shift rod myself? I didn't realize I could remove the shift shaft from the top without removing the internals on the prop shaft, etc.??

 

[AmericanHoney]

This thread does a good job of explaining how to deal with a spinning shift shaft.


http://forums.iboats.com/forum/engi...76-850-installing-shift-shaft-into-lower-unit

 

[Guest]

This thread does a good job of explaining how to deal with a spinning shift shaft.


http://forums.iboats.com/forum/engi...76-850-installing-shift-shaft-into-lower-unit

Wow, wish I would've at least tried that before I took it to the shop...So what is actually causing our problem to happen? Is it when we drop the lower unit, it's pulling the shift rod vertically? thanks

 

[AmericanHoney]

I believe that yes the shift shaft needed to be have been lifted up out of the shift cam, allowing the shift cam to shift out of position. There is a c-clip on the shaft behind the bushing up top that may of moved/fell off allowing the shaft to move up if you never took the bushing out. That would require gaining access to find the clip

In my case I pulled the shift shaft out to pull out the bushing so I could replace the seals. I had it neutral when I pulled it so when I pulled the shaft the cam follower pushed the shift cam out of position.

Mind you this all stuff I have just learned about via the internet over the last couple of days, trying to solve my self induced problem. It seems up front a relatively easy thing to fix and I believe I know what I am suppose to do, but I am fearful of the force I am applying to the shift shaft to get the shift cam to engage with the cam follower. I'm not sure if I just need to turn harder and that would solve my problem or if I turn harder will I break something and create even more problems.

 

[emckelvy]

Sometimes it helps to turn the propeller or the driveshaft while you're attempting to shift. Keep in mind that the shaft turns CCW to shift from Fwd (where there is indeed a lot of slop, which doesn't matter 'cause of the way it's designed) to Neutral. And further CCW to shift to Reverse. Note that you should never try to move the shift shaft more CCW past Reverse as you could possibly damage the shift plunger or other shift clutch parts.

Take a look at this pic of a typical shift cam. As you rotate the cam CCW, it pushes more on the shift plunger to shift from Neutral to Reverse. You can see that if you were to keep turning it, you get to a more flat area that does nothing. That whole area where the cam is flat, and then the rounded part on the bottom, is all the free-motion you feel when turning the shift shaft back-and-forth. And the L/U is in Forward thru all that "slop" motion.

No shifting (out of Forward) occurs until you get past the first "notch" on the cam. Hopefully that explains more than it confuses!!!!

HTH & G'luck.........ed

 

[AmericanHoney]

My cam/shaft moves freely CW or CW for a total sweep of about 200 degrees and then stops. I am assuming that is the cam making contact with the cam follower/plunger?? Being in that free state the LU is in forward, if I understand correctly. So I am turning the shaft CCW, making contact and then turning it with some force while turning the propeller or drive shaft. But it doesn't move any further, should I try apply more force to get it to engage? I assume once it is on the cam follower and just under spring pressure it would move easier, but to get to initially engage does it take some force? Or is it not possible and the insides have to come apart to allow the cam to be placed in the proper position for the cam follower to engage it then the rest installed on top of that?

I am sorry if I am not explaining it well. I'm just frustrated because I think I just need to turn that shaft CCW and get it to engage and change to neutral and things would be proper, but it just seems like I am pushing it too hard that something will break.

You mention that if I go past reverse something else could be damaged. In a sense I am past reverse but I did it by pulling the shaft out of the cam not by turning it. Could the potential for damage still be there?

I guess in a nut shell, I am just trying to know "How hard should it be when turning the shift shaft CCW to get it to engage and enter the real Forward gear"?


Thanks for the help.

 

[emckelvy]

You mention that if I go past reverse something else could be damaged. In a sense I am past reverse but I did it by pulling the shaft out of the cam not by turning it. Could the potential for damage still be there?

I guess in a nut shell, I am just trying to know "How hard should it be when turning the shift shaft CCW to get it to engage and enter the real Forward gear"?

I doubt any damage was done by that. Were you able to retrieve the shift shaft retaining clip? There's always the potential for the clip to go somewhere it shouldn't!

Far as force required, a fair amount. If you're using a 1/4" drive ratchet with small socket to turn the shaft, it would take quite a bit of effort due to the short handle. Even with a rag wrapped around the shaft and a set of Vise-Grips carefully applied, you have to put a bit of effort into it to get it to move to Neutral.

So it may be just a matter of more leverage applied to the shaft. You don't have a lot to lose, since if it ain't shifting you're gonna have to tear the L/U apart to see what's going on.

HTH & G'luck........ed

 

[AmericanHoney]

Thanks again for the help. I was finally able to get the shaft to move past the resistance turning CCW using a bit more force. But it doesn't change gears. It kinda rough clicks in when I first get past the initial resistance and then if I keep apply pressure it rough clicks again and pops out back to free spinning and I have to sweep back around again CCW(about 200 degrees) until I reach the resistance again. From the point of the first click until the it clicks out to free spinning the shaft barely rotates. Looking at the pictures of the shift cam I would of expected it to stay engaged for a bigger sweep. I think I have reached the point of giving up and I'm just going to take it in and get some help.

 

[Guest]

I would have them put new prop shaft seals in while they're at it if you're going to pay them to pull it apart. Sorry to hear, I'm sure they'll fix it for ya.

 

[AmericanHoney]

I thought the same thing about the prop seals. Yeah I'll be glad to check this headache off my list. It is almost ice out so I hope it goes quick.

 

[Guest]

Just heard back from the shop, the previous owner pulled the shift rod up too far and the cam fell off. He said my shift rod was messed up on the end so he ordered a new shift rod, and bushings.

He's also going to put new prop shaft seals on. Total charged time is an hour and a half + parts. Probably set me back around $200. Considering that and the new water pump I'm putting on, I shouldn't have to touch the lower unit for quite a while. Best of luck with yours bud.

 

[Guest]

Just a heads-up, I hope you don't have to pay what I'm about to pay.... $440 for prop shaft seals, shift rod, and fixed the shifting issue...wtf.