Shift Cable Adjustment (not a procedure ques)

[haulnazz15]

I couldn't get the lower unit to engage both forward and reverse gears from the helm, so I took it to a repair shop. I expected to have a lower shift cable replacement since mine is likely the original 30+yr old shift cable. I was able to manually shift the outdrive into F/R, so it's not the drive that I can tell. The (Merc pre-alpha) outdrive has new lower and intermediate shift shafts and was shifting prior to us taking it off, removing the engine for a repair, and reinstalling. When we reinstalled the outdrive, we accidently bent the brass intermediate shaft when it got caught on the upper shift shaft. I pull the outdrive apart and replaced the already new intermediate shaft with a new one.

Here's the rub: after the shop installed the new lower shift cable they have told me that they still can't get it to grab both gears and were going to take some measurements.

What measurements would they need aside from the initial measurements for the lower shift cable? I just don't want this turning into a $1K repair when the lower shift cable installation should just be $350. I don't see where the issue could possible lie?

 

[sethjon]

Re: Shift Cable Adjustment (not a procedure ques)

I couldn't get the lower unit to engage both forward and reverse gears from the helm, so I took it to a repair shop. I expected to have a lower shift cable replacement since mine is likely the original 30+yr old shift cable. I was able to manually shift the outdrive into F/R, so it's not the drive that I can tell. The (Merc pre-alpha) outdrive has new lower and intermediate shift shafts and was shifting prior to us taking it off, removing the engine for a repair, and reinstalling. When we reinstalled the outdrive, we accidently bent the brass intermediate shaft when it got caught on the upper shift shaft. I pull the outdrive apart and replaced the already new intermediate shaft with a new one.

Here's the rub: after the shop installed the new lower shift cable they have told me that they still can't get it to grab both gears and were going to take some measurements.

What measurements would they need aside from the initial measurements for the lower shift cable? I just don't want this turning into a $1K repair when the lower shift cable installation should just be $350. I don't see where the issue could possible lie?

Without seeing I'm not sure but its possible they routed the cable wrong. Doesn't take much. the new cable should work perfectly. Also, the $350 number is about right...no more.

 

[haulnazz15]

Re: Shift Cable Adjustment (not a procedure ques)

How could they have routed it wrong?! I'm only aware of one way that it could be installed. The only point of concern would be the fact that I think it is the old style cable which is threaded forward in the bell housing as opposed to the newer style which threads on the aft end. Either way, the new cable just needs to have the threads tapped in order to work.

Are there any other areas that would cause this issue? I can't imagine there being too much slack in the shifting mechanism in the drive itself, and the upper shift shaft appeared to be in good shape.

 

[rodbolt]

Re: Shift Cable Adjustment (not a procedure ques)

its the gimbal housing that has to be retapped. done correctly with the correct tap takes a few minutes.
there were several shift mechanisms for the lower.
the shift spool play can be measured with a template provided in the service manual.
if the shift spool play is acceptable then its gonna be in the cable anchor installation or possibly the cable betwwen the helm and the shift transfer block.

 

[Fishermark]

Re: Shift Cable Adjustment (not a procedure ques)

the shift spool play can be measured with a template provided in the service manual.

Here's a video where I tested mine recently with the template:

testing shift spool play

Mine ended up being borderline worn out. (The good news was that this was on a SE106 and Sterndrive Engineering rebuilt the lower unit at no cost and no hassle).

 

[haulnazz15]

Re: Shift Cable Adjustment (not a procedure ques)

Interesting. I might call them tomorrow and ask if they've checked the shift spool measurement to be 12-degrees or less. Otherwise it looks like an SEI drive for me. ughh

 

[dubs283]

Re: Shift Cable Adjustment (not a procedure ques)

How could they have routed it wrong?

i've seen factory installed shift cables routed wrong

there are no more "old style" cables, at least not new in box, unless somebody has a lot of old stock sitting around

6" in fwd gear, back off four turns if no shift assist - that is the measurement, done...install the cable and it should go into fwd gear, if not something is installed wrong

sometimes you may have issues getting it into reverse, just move the cable end up in the slot and test shifting - never fails

if you STILL have issues and you know the drive/installation is good, check cable play from remote to engine

 

[haulnazz15]

Re: Shift Cable Adjustment (not a procedure ques)

Yeah, those are the measurements I was familiar with, so that's why I didn't really know what "measurements" they would be making since they should have done that 6" measurement for the new cable installation.

 

[haulnazz15]

Re: Shift Cable Adjustment (not a procedure ques)

Okay, so here's the newest information: The shop has replaced the lower shift cable and taken measurements at the shift slide/shift shaft. He thinks that he isn't getting enough travel from the shift cable (they just installed) and are ordering a new shift arm for the shift plate on the engine which will increase the travel of the cable. Does this seem right?

The current shift arm is the original and never had an issue before, so why would it cause an issue? I know it had the old-style lower cable that threaded into the forward part of the bell housing, and the new cables thread into the aft-portion of the bell housing. Can that affect the shift arm travel?

Is it possible that the upper shift shaft (on the bell housing) is twisted or bent somehow not allowing full travel? I just don't want to spend $1K+ fixing this issue!