Shift cable? Lower unit? I just can't seem to hit the gears right.

[JSavage]

Ok,

3.7 Merc with an Alph 1 Gen 1.

I picked this boat up a couple of years ago and can't for the life of me seem to get everything to work all of the time. Right now it's a shift issue.

Replaced the lower shift cable last year along with the gimble bearing and all bellows. Now, I can't seem to get the setup right. I shift into reverse and it doesn't catch. If I reach under and push the dog the tiniest bit more, it locks in. Forward seems to hit right where it should. I can't detect any slop in the system. While I haven't put the scale on it and checked the degrees of play in the lower, I can almost NOT move the dog when forward is locked in so I suspect I'm under 12 degrees.

Anyone have a good starting point for me?

Thanks.

 

[stonyloam]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Try adjusting your cable: Start at page 90: http://www.perfprotech.com/store/app_themes/ppt/images/tech-specs/alpha-shift-adjust.pdf

 

[JSavage]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Just got done with adjusting. Still can't hit rev right. If I push the dog just the tiniest bit past the stopping point of the shift cable, it will engage Rev. I just changed that shift cable last year near the end of the season... any thoughts on maybe I didn't get it seated well in the drive? Maybe stopping the cable from traveling all the way?

 

[stonyloam]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Well if you are under 12 degrees, your shift spool should be OK. I wonder if the top of the intermediate shift shaft or the bottom of the upper shift shaft might be twisted. It could have happened sometime in the past if the outdrive was removed improperly. Put it in forward and look underneath to make sure nothing is twisted. If it is the i ss it might be very hard to see, so it may be necessary to split the outdrive to determine if that is the problem. If you disconnect the cable at the engine and pull it by hand will the reverse engage?

 

[achris]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

How about the slot in the end of the shift lever? Did you adjust the cable mounting stud?

Have a look at this to understand what I'm talking about...

Shift cable adjustment: http://youtu.be/-s_tgevX2aI

Chris.......

 

[JSavage]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

That was a great video. Really explained the shift system well. I'm saving that for future reference.

To the other question, I cannot engage rev by pulling on the cable. At one point, I actually adjusted the lower out to the point that it tripped the cut out and it still didn't lock in. That's what has me thinking I screwed the install.

The shaft doesn't look twisted. In forward, it points exactly straight ahead. In reverse, it turns port, and looks like it turns pretty far, but not quite far enough to engage reverse.

When I changed it last year, the thread area was pretty corroded. The brass end screwed in hard and I didn't dare take it out again. It's got me wondering if it seated and regretting not chasing the threads with a tap to make sure they were clean.

I guess any way I look at it, the drives coming off again, unless someone has an extre pair of xray glasses.. I might do that tomorrow. Once I do, I'm going to confirm that the spool has less that 12 degrees of slop.

 

[stonyloam]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

The only things that I can think of are: The upper shift shaft lever might be loose on the upper shift shaft. It is held in place with a pin that screws into the lever and goes through the shaft, make sure it is tight and not bent. The top of the intermediate shift shaft might still be bent, when you take the outdrive off, turn the shaft all the way clockwise to make sure it still points straight ahead. The last is of course the shift spool, check foe 12 degrees or less. Hope you can get it sorted out.

 

[achris]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

How did you go with the 9/16" slop measurement? More or less?

Chris.......

 

[1977 SILVERLINE]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Check your upper shift shaft bushing. When I changed my impeller I replaced this bushing just because it felt loose. It was surprised when I drove it for the first time how well it shifted into gear. Before the bushing was replaced it wouldn't always lock into gear right away.

 

[stonyloam]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Silverline +1, it could probably use an update to the new style seals anyway: http://www.mercruiserparts.com/showSpecialPicture.asp?pn=805041A2 pn 28-805041A2

 

[JSavage]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Ok,

Took the drive off and clocked the spool at 5 degrees. Took a look at the intermediate shaft and it was a little bent and a little twisted. Thank god for brass... Put a little heat to it and straightened it out. Tossed it back on without new gaskets just to see what I had and it hits forward and reverse by pushing/pulling on the cable. I don't even have to hold tension. Thanks much for that advice. I would have sworn I screwed up the shift cable install but it was the shaft after all.

That's why I love this place though. I'm a disabled vet and full time nursing student with a wife and 2 brats... there's just no way I could shell out the cash to have a real tech look at it.

Any other suggestions before I get a new impeller and gasket set?

 

[stonyloam]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

. there's just no way I could shell out the cash to have a real tech look at it.

Any other suggestions before I get a new impeller and gasket set?

Uhhhh Thanks I guess that is a compliment

Just the new upper shift shaft bushing and seal.

Thanks for your service!!

 

[JSavage]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

It was, Stony. A big compliment and and big thank you! Thanks to all of you. I just realized I want to rewire and replace all of my instruments and a new carb. I'm probably ill but what the hell... I paid 450 for this boat 2 years ago and only put a starter, ignition switch, and a lower shift cable into it, well a little vinyl work too. I'm sure I'll be seeking more advice before too long. I just hope I can pick up some tips to pay forward some day.

 

[Eric 3.7LX Alpha 1]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

It was, Stony. A big compliment and and big thank you! Thanks to all of you. I just realized I want to rewire and replace all of my instruments and a new carb. I'm probably ill but what the hell... I paid 450 for this boat 2 years ago and only put a starter, ignition switch, and a lower shift cable into it, well a little vinyl work too. I'm sure I'll be seeking more advice before too long. I just hope I can pick up some tips to pay forward some day.

Sounds like another Iboat addict is born. Tell your wife we're sorry!!

 

[stonyloam]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Here is what I do to keep my outdrive in good shape. Pick up a couple of cheap grease guns, ten bucks or so at Wally World, then over to your Merc dealer and pick up a tube of U-joint and spline grease and a tube of 2-4C. Use the spline grease to lube the splines on the driveshaft, gimbal bearing and u-joints. Use 2-4C everywhere else, gimbal ring and propshaft, even a little on the impeller when you install it. Merc stuff is expensive but will be enough for years. The only other thing is to retorque the gimbal ring clamping screws (two screws on top of ring) to 55 lb., that will keep your outdrive tight. All that should be done every year, and the impeller on a 470 should be done every other year. Oh here is a link to your engine manual: http://boatinfo.no/lib/mercruiser/manuals/mercruiser8.html#/0 Have fun.

 

[JSavage]

Re: Shift cable? Lower unit? I just can't seem to hit the gears right.

Thanks I have the manual already as well as #6. I'm pretty religious about greasing but never though of those screws. I'll have to do that.