shift shaft too short, won't reach shift lever in new upper

[harrytrumanagain]

Have just re-assembled entire outdrive, adjusted shift cables etc. in an alpha 1 gen 1 sterndrive and (as I noticed as I was attaching lower to the upper) the shift shaft is about 1/4 to 1/2 inch below shift shaft slot. The upper is a new refurbished unit from SEI. The lower is a used one that seems sound in which I replaced the water pump. The shift shaft is the original one (the only remaining piece of the outdrive.) (I have run out boards for decades but am new to stern drives). I realized this might be an issue, and now I see they have to mate to operate properly.

 

[harringtondav]

Verify the lower shift shaft is engaged in the shifter yoke (fork) in the lower housing. Holding the foot forward see if the prop. shaft locks CCW. With the foot as far CCW as it will go (about 10:30) the prop shaft should lock CW. If the shift yoke (fork) is missing or misassembled, the shaft could be dropping too low.

 

[harrytrumanagain]

The shaft is engaging the prop in both directions as I determined when adjusting the shift lever cables.

 

[harringtondav]

The shaft is engaging the prop in both directions as I determined when adjusting the shift lever cables.

Then I'm out of experience based suggestions. My next suspicion is the SEI upper may be a Gen II, with a different length to the joint surface. There are plenty of sage gurus on this forum that could address this possibility. A Gen II lower shaft my be needed, but the pros will know.

 

[Bt Doctur]

A GEN II type can never mate with an Alpha 1 so if the brass shoe in the drive does not mate with the U part in the housing then you forgot to install the SS washer on the lower splined shift shaft.
SE106= Alpha 1
SE116 =Alpha GEN II

 

[harrytrumanagain]

I looked in the manual and did not see a reference to it. would you know how to find out what it looks like and how to install it? Thank you, the distance sounds just about right for a fairly thick washer.

 

[Rick Stephens]

 

[Fun Times]

^ Which is item number 52 12-8M0042641 --WASHER, (.390 x 1.00 x .06) , https://www.mercruiserparts.com/bam/subassembly/30870/2203/110

https://www.ebay.com/itm/Sierra-18-...531040?hash=item2ef7998ce0:g:JjIAAOSwHMJYLwXq

Also be sure washer number 22 is in place,
https://www.mercruiserparts.com/bam/subassembly/30870/2203/60

 

[Bt Doctur]

look around where you did the repair, I`m sure you`ll see it on the ground

 

[stang32]

look around where you did the repair, I`m sure you`ll see it on the ground

+1, i have had a drive that was missing that washer sometimes the washer gets stuck to the shaft and upon removal, when it is set aside, then it falls off

 

[stang32]

if you cant find it, a stainelss washer from HD will do the job

 

[harrytrumanagain]

Thanks everyone, I found a washer that fit in my stainless steel inventory and put it in and it mates like it should. (I also found I had omitted a very thin shim held in place by a cotter pin that was not present when I removed it from the old unit - fixed that too - thank goodness for spare parts!)