Shift Shaft 815919A1 won't seat properly

[alorio1]

While replacing my impeller, I thought I would dislodge my speedo passage by blowing compressed air thru quick connect located near impeller. I could not get the passage way cleared so I pulled the shift Shaft 815919A1 and when I pulled the shaft up I heard a distinct click. I got the passage way cleared out and when I wen to reinstall the shift shaft it does not go all the way down into place, with about 3/8" gap between housing and shaft holder. I shined a light down in the hole and there seems to be a pin lying in the bottom of the shift shaft hole that is probably the reason the shaft is not seating. What do I need to do to get this pin back to it's proper location so I can reinstall my shift shaft that will allow it to be seated correctly? I have search the forum but did not find anyone with this shift shaft problem that posted up their solution to this problem I am encountering. Thanks in advance to anyone who can help resolve my issue, alorio1......This is an Alpha 1 gen 2 outdrive number 0D797230

 

[84EdH]

Re: Shift Shaft 815919A1 won't seat properly

I don't have a gen 2, but I looked on a parts diagram for your drive number. no "pin" shown as part of the lower shift shaft assembly. did you recover the e-ring that fits on the bottom of the shaft? I presume you have a parts diagram as you have the correct shift shaft number.

 

[alldodge]

Re: Shift Shaft 815919A1 won't seat properly

No expert here, and looks like we need to have achris to have a look here. I think I found the pin your talkinh about but I would guess it could be spring loaded so tp speak. It's part of the shift spool kit item 40 which is connected to item 39 shift crank. The shift shaft appears to slide in the top of the shift crank, should go past the shift spool then back into the other side of the shift crank.

Hope achriss will see and comment

http://www.mercruiserparts.com/Show_pictures3.asp?dnbr=818183 91&ivar=IMAGES/COMMON/13838.png&inbr=1017&bnbr=90&bdesc=Gear+Housing%2C+Propeller+Shaft+%2D+Standard+Rotation

 

[alorio1]

Re: Shift Shaft 815919A1 won't seat properly

I'm afraid achriss's prognosis is gonna be the lower unit will have to be disassembled to get the shaft connected to the shift crank. I can see the E-clip and what appears to be a splined washer down in the hole. This could be a bad deal for me just because I wanted to open the speedo passage. But if thats the case I will remove the new pump and switch it over to another lower unit I have that can be made useable for now.

 

[Bt Doctur]

Re: Shift Shaft 815919A1 won't seat properly

Should have asked how to remove it before you removed it. Shaft and bushing are removed as a unit. All is not lost yet.
try a small magnetic wand or make one from a small dowel and the magnet from a lower unit drain plug.
try to recover the 2 items. Failure to recover them means dis-assembling the lower completely.
Should you get lucky and remove them install them back on the rod.
WITHOUT JIGGLING THE LOWER UNIT ANY MORE THAN NECESSARY try to install the shaft.
should you dislodge the "C" selector

you will need to disassemble the lower completely.

 

[84EdH]

Re: Shift Shaft 815919A1 won't seat properly

if the parts are stainless steel, the magnet wont work. if so, put some duct tape on the end of a stick and try to to fish them out.