My first outdrive install - drive 1 me 0

[John_S]

'97 Alpha 1 genII ser 0K044042<br /><br />Got home from work this evening, and it was decent weather for a change. Decided to try to get the drive installed.<br /><br />3M'ed gasket adheasive for the large outdrive O-ring and the water connection O-ring. Re-checked the engine alignment, still good, it had even spline marks in the grease, on the end. <br /><br />Drive install stoped just short of the studs. I believe it is where the splines should go into the engine coupler. I tried 3-4 times jigling the drive around and turned the input shaft a little, but no go. <br /><br />Outside of this, I might also have a shift cable issue. Even though the shift lever is in WOT forward position, the slot is still at an angle. See the 2nd picture below. There is some spring pressure pulling back on the cable. As you can see, I'm using a closepin to hold the shift cable end, not the specified merc tool. From the picture in the manual, it doesn't look like the tool pulls on the cable. FWIW, I did not have any shifting problems, clunks, or stalls, before drive was pulled for winter. <br /><br />Any thoughts, hints, or secrets?<br /><br /><br />

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[JustMrWill]

Re: My first outdrive install - drive 1 me 0

I know that with my OMC...it took about 10 minutes of "nudging" the u-joints clockwise..push...nudge...push..until the splines lined up..then it just slipped in. I don't know much about Mercs...but if they need to be in gear for removal/installation..then I would think that the "nudging" could be done by rotating the prop shaft. Good Luck.<br /><br />-JMW

 

[Don S]

Re: My first outdrive install - drive 1 me 0

You don't have the shifter in forward!!!<br />From the looks of the shift shaft in your lower picture, it's in the neutral position.<br />Put the shifter in forward, then put the drive in forward so the shift shafts line up. Keep a CCW pressure on the prop while putting the drive into position. Then when you feel the drive shaft hit the coupler, just turn the prop a little bit CCW to turn the shaft and while pushing forward you will feel it go into the splines.<br />Then check the shifter bracket you have the close pin on to make sure the roller is between the pins and push the drive forward. The orings on the shaft may give a little resistance in the last 3/4"

 

[rodbolt]

Re: My first outdrive install - drive 1 me 0

before ya button it all back up get a flashlight and inspect the seals where the shift shaft enters the ex cavity, that rust looks like a seal may be failing. fixing failing seals now can save a shift cable later.

 

[Bt Doctur]

Re: My first outdrive install - drive 1 me 0

definitely not in fwd by the pic.when you shift dont push the button it, just shift it like it was running.also check for any surface rust on the input shaft.

 

[John_S]

Re: My first outdrive install - drive 1 me 0

Don, the lever is fully forward. I will check tomarrow, to make sure that warm-up button wasn't pressed in. There is a good chance, that is what happened.<br /><br />Rodbolt, I'll check on the rust. I think the picture makes it look more like rust, than it is. Do you just punch the pin out, and that shaft will drop down? Seals looks like they are just below the upper bushing. <br /><br />Round 2, tomarrow evening.

 

[Bt Doctur]

Re: My first outdrive install - drive 1 me 0

unless im mistaken that pin is screwed in place. should be a spot to use a flat screwdriver

 

[Don S]

Re: My first outdrive install - drive 1 me 0

I think you better save round 2 for the link below.<br /><br /> http://www.boatfix.com/merc/Servmanl/14/14cover.pdf <br /><br />Go to section 2 for Removal and Installation. Seciton 4B will explain how to replace those seals.

 

[John_S]

Re: My first outdrive install - drive 1 me 0

Bt, just checked the manual, you are correct it is called out as a screw.

 

[John_S]

Re: My first outdrive install - drive 1 me 0

What a difference a day makes!!! <br /><br />First, the shift rod issue was the button pushed in. Once it was in fwd, it was nice and straight.<br /><br />2nd, inspection of the shift cable cavity found no rust. I gave the shift lever, exposed shift cable, and cable end, a light coat of special 101 grease. <br /><br />3rd, the clothespin does work as a cable positioning tool.<br /><br />4th, drive went in the first attempt, with a little turning of the prop shaft. <br /><br />Drive is torqued in, and trim cyls attached. Should be able to fire it up, in the driveway, this weekend. <br /><br />Thanks for all the hints and help.