OMC 3.0 Reverse Gear Problem

[Neckpants]

I have a 1989 Four Winns 160 Freedom with 3.0L 4cyl I/O. At the start of the 2014 season the u-joint and exhaust bellows were replaced, lower unit reinstalled and lube checked. Shift cable was replaced and shift linkages set to factory specifications at the end of the season in 2011. All maintenance has been performed by a OMC certified mechanic in the Boston area.

Problem: Forward gear works smoothly but when trying to engage Reverse the engine will rhythmically sputter( and stall if I let it) and it does not engage(R). Although it was never a smooth transition, the gears F-N-R worked without an issue last season. I am not a mechanic but I'm aware of the potential problems with OMC shift linkages and would prefer to have an expert take a look. Before I bring in for service are there any recommendations of things to try? From what I gather it could be an issue with the transom shift cable, ESA System, or the shift rod height adjustment.

Thanks in advance for any input!

 

[vinnie1234]

Sounds This will be ESA or cable seizure. Check ESA first, disconnect the switch. It shouldn't sputter anymore. If it still wont go into reverse, then check all cables at the intermediate - start with the cable adjustment coming from the helm control.

 

[Neckpants]

This ESA on this engine is original so I am hoping its just time for a replacement which, for this model engine, is relatively cheap. Thank you.

 

[HT32BSX115]

Howdy,


The ESA should NOT activate when going INTO gear (FWD or REV)

If it is, the lower shift cable, associated linkage ,or the drive (internally) is likely binding.

All maintenance has been performed by a OMC certified mechanic in the Boston area.

Maybe not. It's been many years since OMC conducted those schools and people who actually attended them are probably retired by now (or dead).

Be wary of people claiming to know all there is to know about the Dog-clutch Cobras.

Whomever you have work on it, be sure that they are using an OEM Service manual for your model and are familiar with http://www.hastings.org/~stuart/cobra/

Good luck,


Rick

 

[Neckpants]

No Title

Be wary of people claiming to know all there is to know about the Dog-clutch Cobras.

Whomever you have work on it, be sure that they are using an OEM Service manual for your model and are familiar withhttp://www.hastings.org/~stuart/cobra/

I have seen the Hastings link and I'm currently ordering an OEM manual before they all disappear(Will make sure my mechanic has a copy as well). The boat is going in this week so I will have an answer for you soon. *Attaching some pictures that seemed to have been erased from my initial post.

 

[Neckpants]

The problem was actually in the outdrive if you can believe it(and I'm sure anyone with an OMC can). The outdrive had to come off after some basic diagnostic work and it was obvious that the shift rod was spinning because the shift rod pin had come loose. The mechanic was able to find the pin and reassemble.
During the process it was obvious that some water had creeped its way into the outdrive because of leaks in the upper U-Joint seal and the Bearing carrier R-ring. In addition to bad seals there was some obvious pitting on both parts. The corroded bearing carrier(housing assembly) was replaced with a used part that was in great shape. The outdrive was sealed (upper & lower) and pressure tested successfully.
Although this was a lot more than I bargained for, I am glad that the leak was found before too much water got into the outdrive and ruined the gears.