Shift cable stuck in the sheath

[timharper89]

Trying to replace my shift cable in my alpha one gen 1 4.3L. Following this video https://youtu.be/PZN-HHuIDPI, I got to the part where you pull the shift cable put of the sheath from the transom side. I removed/disconnected everything up top (upper and lower disconnected, lower shift cable end removed, removed "jam nut" and "threaded shaft"). Next step is to remove the cable from the sheath. Mine won't come out. It's there something I'm missing? It moves about 3" and stops. Do I need to somehow take the silver piece (pictured) off first? Also attached a picture of the lower shift cable from the engine compartment. Thanks for the help

 

[timharper89]

Btw I'm replacing my bellows as well. Anything I should take care of while I have it apart?

 

[Bt Doctur]

Your trying to remove the control cable that goes to the control box, the lower shift cable has the brass barrel

 

[Bt Doctur]

watch the video again at the 1:16 point

 

[timharper89]

When I pull the cable from the top, it pulls the cable in from the bottom (the one I'm trying to remove). I traced the cable ,and it goes down behind the engine block .The other two cables go toward the front. I've attached pictures of what I've taken apart on the engine side. The one with the brass barrel is directly controlled by the shifter by the steering wheel even while disconnected. Following that cable goes to the front of the boat. Are you saying that is the one I should be trying to remove from the transom? Do I have upper and lower confused? I'm trying to pull the shift cable from the outdrive.

 

[timharper89]

https://photos.app.goo.gl/7HfBrvjsK7akDWFx6

 

[Bt Doctur]

In the video the cable moving is the control box cable not the lower drive cable
No lower control cable has a plastic barrel for adjusting

 

[Bt Doctur]

 

[Bt Doctur]

control cables

 

[timharper89]

Ok the video/ picture is the NOT one I'm trying to remove. The picture in the OP is the one I'm trying to remove. I followed the video step by step, but it just won't come out. Do I need to pull really hard? Seems like it should just come out. I'm 99% certain I have the correct cable. Here is another video https://photos.app.goo.gl/6zDbExYJ51iZ5Bek9
​​​​​​

 

[timharper89]

Another video from the top as I pull at the bottom https://photos.app.goo.gl/9DcbMLJtmpHTktpd7

 

[Bt Doctur]

Now I see the problem , there is a SS sleeve on the inner core that must be removed first. Give the grey slide a very hard yank and the core will come out and leave the sleeve. When replacing the old style with the newest style you will need a special tap for the threads. The newest cable does not use the sleeve and does not have to be measured and cut to the correct size. Same cable that is used on the Alpha GEN II models

 

[Bt Doctur]

http://www.boatfix.com/merc/Bullet/83/83_27.pdf

 

[BF]

I just did the lower shift cable on my Alpha 1 Gen 1... mine is a 3.0 but same parts/procedure. If you still have the outer cable sheath routed up to the top of the engine, the bends in the sheath will bind up the non-flexible engine-side end of the inner cable. Try straightening the sheath (with inner still in it) by moving it out from behind the steering stuff, and lay it under the engine so it is straight and laying beside the front engine mount. That takes most of the bend out if. Mine pulled out easily... You do have the clamp or zip ties on the shift bellows off, right? If you're also replacing the outer sheath, it should be laying that way (straight) so that it will turn as you loosen it from the outdrive. If you loosen it while it is still bent and routed to the top of the engine, it will bind/kink and not turn freely inside the boat as it is loosened. Before you pull the outer sheath out, don't forget to reach in from the boat side and remove the white plastic sheath protector... It should be on the outer sheath about where it passes close to the exhaust Y. Likewise when tightening the new sheath, have it straight so that it can turn as you twist the cable to tighten it. Leave it straight until you push the new inner into it. Then route it properly around the steering stuff and back to the top of the engine.

Hope this helps...

 

[Bt Doctur]

You cant remove a old cable core until you remove the SS sleeve first, considering the end of the sleeve gets crimped.
Easiest way to remove a "old style" is cut the cable at the front of the housing and use a deep socket

 

[BF]

OK, sorry if my post was misleading... my Alpha 1 has the new style, bolt on the prop side of the outdrive type of outer sheath. FWIW, once you convert to the new cable set, my advice of needing to have the new sheath straight to be able to push in the new inner stands.... I did not do that (routed the sheath up to the carb area first), and found I could not push the inner in. The end couldn't get through the bends. I had to move it back down under the engine, then the inner went in fine....

Good luck...

 

[Bt Doctur]

The 3.0 is super easy in most cases, Where the difficulty arises is where you cant even see how it routed. The trick here is to remove the old core, and use a core from a control cable as a guide when you remove the old sheath leaving the SS core in its place.Then slide the core thru the new cable, hold the end of the core with vise grips and with another person in the boat to pull the core while you push the sheath.
For Tim

 

[timharper89]

Thank you! I didn't want to pull really hard and break something. Took a bit of finding, but I got it out .Thanks again.

 

[timharper89]

Can I just use the old cable as a guide? The cable cable is intact ,it's the sheath that's bad
​​​​

 

[Bt Doctur]

dont know how you can use the old inner core, ,its a bit short .Some have used weed trimmer cord but I prefer the solid SS control core