Mid 90's 40 HP Evinrude Tracker Outboard won't stay in gear - Help

[bscheper]

I have a mid 90's 40hp Evinrude Tracker outboard on a pontoon. Last year when I put it in forward the engine popped in an out of gear. So I fixed the problem by adjusting the shift linkage at the engine and now it will go in forward fine but when I put it in reverse it pops in and out of gear. I tried to adjust it many times but could never get it to shift completely into forward and reverse at the same time. What is the cause of this? Any help is appreciated. It is as if the shift lever does not move the shift linkage/arm far enough.

 

[henleyhale]

There is linkage under the powerhead that must be taken apart to get the lower unit off, if that linkage is loose it can cause this type of play, i remember it being a pita every year. Also on the control if the slides anchor nuts came loose it can shove a bit of cable through shortening the cable that can cause this.

 

[jakedaawg]

Many possibilities here. Worn linkages. Worn clutch dogs. Stretched cables. Worn controller....

If you remove the cable can you shift it by hand and have it work properly?

 

[bscheper]

I will try shifting by hand this weekend and let you know. If it shifts good by hand then I am guessing that my problem is in the controller or cables and now down in the linkage in the shaft or clutch dogs?

 

[boobie]

Yes..........

 

[bscheper]

Looks like it is the clutch dogs according to the mechanic I had look at it . He said lower unit gears are expensive for this and will run approx $1200 plus install. About right? Any better fix options? Buy whole lower unit?

 

[bscheper]

Is there an additive I can add to lower unit gear lube that would help temporarily?

 

[jakedaawg]

nope

 

[racerone]

Take the time to read a manual.---Read about " shift rod height " as well.--Take the unit apart for inspection.---Then decide what parts need to be replaced.-$1200 sounds high .----Shops have to make sure it is fixed the first time or they have an upset customer / make no money.--When you understand how it works you will realize that an additive simply does nothing in this case !

 

[bscheper]

The longest project ever. Still having issue this year but took a look while out of water this spring. Put in reverse with control box and didn't go all the way into gear. Pushed shift lever backwards by hand and it moved another 3/4 inch and it went all the way into gear. Now do you think it is cable or control box? Where can I find new box/ cabels for te40elenj. Side mount on pontoon rail. I have looked on line for housing with no luck. Single lever with separate neutral idle lever. No trim.

 

[jakedaawg]

Probably cable, have you inspected it? The barrels must be tight to the casing. Take one end off and see if it moves without moving the other end. Make sure the casing is intact for the entire length.

 

[bscheper]

Thanks. Great idea to try. If it moves I will be taking good box apart and replacing. I hate taking those boxes apart with all the small pieces. But I have done it before. Makes sense that it is the cable because I could move shift lever at engine with cable connected and shift lever did not move on control box.

 

[jakedaawg]

If your careful, you can open the box, replace cable, and not have any of the stuff fall out. At least it shouldn't if it is asssembed correctly. Just note which hole on the shift arm the cable attaches to. Also don't buy a universal cable or some cheap crap. Buy the right cable and it's just three screws on the box with a #3 Phillips and I believe a 5/16" socket to remove the cable from the arm. When reassembling the box sometimes you need to lift the fast idle lever slightly to get the cam follower in the groove. Easy-peazy. Take more than 20 min your doing something wrong.

 

[bscheper]

Thanks for info