Shifting frustration

[dhisl0]

I have replaced the shuft cable in my Alpha One outdrive and had the gears machined in my lower unit. The shift cable works fine by itself and the outdrive works fine but when I attach them I only have two gears-forward and neutral no reverse. I have all three gears when the outdrive and cable are seperate but putting them together causes the problem. Any suggestions as to what is causing the problem?

 

[Bart Sr.]

Re: Shifting frustration

Did you make sure the shift lever AND outdrive were in the forward setting before reconnecting the cable??

This is a common oversight.

 

[Fishermark]

Re: Shifting frustration

when I attach them I only have two gears-forward and neutral no reverse.

Do you mean that you have trouble getting into neutral when you are operating the boat - or does it do it even when you shift the control box without the engine running?

If it is only when operating the boat, then I would suspect the interrupt switch... otherwise, not sure.

I did have a problem once that was difficult to diagnose. With everything separated, it shifted fine. When put together it would bind and be difficult to shift - even with a new cable. Turned out the intermediate shift shaft was slightly bent, causing a bind when assembled. You might check that.

 

[dhisl0]

Re: Shifting frustration

Shift cable and outdrive were in forward when connected. I have the boat started and it shifts fine into forward and neutral but will not go into reverse. When I had the outdrive out, I straightened the intermediate shift shaft as it was bent. Good suggestion. What else can I check?

 

[Fishermark]

Re: Shifting frustration

I guess I would verify that the shaft is truly straight - or even replace it as it doesn't cost much. Also - did you remember the washer? It is easy to forget, and you will not be able to shift correctly without it:

 

[dhisl0]

Re: Shifting frustration

Yes I did remember the washer. I was told that it is very important. The shaft looks straight. Guess it could be off just a little. But would that keep it from completely going into reverse? I cannot get it to go into reverse at all. It just stops at neutral and will go no further.

 

[jtybt]

Re: Shifting frustration

I don't know what you mean by having the gears 'MACHINED'.

The gears are already machined and shimmed to the correct tolerances.

No one machines gears.

 

[dhisl0]

Re: Shifting frustration

The edges of the gears in the lower unit were rounded and my machinist said he had machined his gears and they did fine. He straightened the forward and reverse gears and the sprocket. Would this make me lose a complete gear?

 

[jtybt]

Re: Shifting frustration

NO!

The gear in an alpha are always engaged and are constantly turning when the engine is running. Your machinist may be talking about the dog gears. The dogs engage by sliding from neutral to either forward or reverse. They have a finite amount of travel. Excessive machining reduces the amount of engagement. Older drives had a certain amount of adjustment to the total throw of the dog clutch. That was the shift interrupt plate with the slot in the lever that the end of the shift cable attaches to. Moving that anchor point farther from the axis will increase thew amount of travel. You may need it.

At this point I don't know exactly what was done so don't do anything until it's clear what he did.

 

[dhisl0]

Re: Shifting frustration

The only thing the machinist did was to straighten the edges on the gears. The lower unit shifts great when it is out of the boat. The shift cable shifts great when it is not attached to the outdrive. I have no problem when the outdrive is attached and shifting gears with the engine. Engine runs smooth regardless of what I do with the outdrive. Something is hanging up when the outdrive is attached to the shift cable and I cannot figure it out.

 

[jtybt]

Re: Shifting frustration

Was the lower removed from the upper or was the whole drive removed and then separated?

 

[dhisl0]

Re: Shifting frustration

The outdrive was removed as one unit then upper seperated from lower.

 

[dhisl0]

Re: Shifting frustration

Are you wondering if the two halves are correctly connected together? How can I tell if they are operating as one unit? I can see the prop turn when I turn the coupler on the lower unit so I know the gears are properly engaged there.

 

[Fishermark]

Re: Shifting frustration

Well, I have never heard of anyone "machining" the gears.... but I'm no expert in that area. I will leave that to others for input as to whether or not that is common or advised.

The best thing I can suggest is taking things off and starting again. Remove the entire outdrive and then separate the halves. Be sure to put the lower in forward gear - you do know how to do that, correct?

Assemble the upper and lower. Then put it back on the boat. Try it then. Beyond that, I am out of suggestions.

 

[windsors03cobra]

Re: Shifting frustration

Sounds like the shift shaft and dog have worn beyond operable limits, my 1977 is on the brink. Into reverse the revs start to climb as reverse engages. Into forward it thunks in nice, I have it adjusted to operate forward a little better than reverse as I use forward more.
All my throw settings are maxed, I gained a good 1/4 inch maxing the control box shift cable :redface:

I get neutral from both directions nicely, fresh lower cable.

 

[smithrock]

Re: Shifting frustration

Sounds like the shift shaft and dog have worn beyond operable limits, my 1977 is on the brink. Into reverse the revs start to climb as reverse engages. Into forward it thunks in nice, I have it adjusted to operate forward a little better than reverse as I use forward more.
All my throw settings are maxed, I gained a good 1/4 inch maxing the control box shift cable :redface:

I get neutral from both directions nicely, fresh lower cable.

Having pretty much the same problem! New lower cable forward goes in like butter! reverse chatters and goes in then out then in? Which way did you turn the barrel for more travel into reverse?

 

[windsors03cobra]

Re: Shifting frustration

Having pretty much the same problem! New lower cable forward goes in like butter! reverse chatters and goes in then out then in? Which way did you turn the barrel for more travel into reverse?

T'was 6 months ago, I did it the way to book said to do it, I also backed the throttle cable barrel back a few turns on the engine so it does not increase the revs until a smidge after the throttle detent starts.
Positive quick throws on the control lever helps get it in gear better than slowly pulling into gear, doesn't take long to adapt and figure out how the machine likes to work.
My wife operates its with no problems so I guess I have it working pretty good. I sure did not want a one man horse.

 

[jtybt]

Re: Shifting frustration

A couple things to check. The lower shift shaft is splined. The 'foot' has splines that slide over the lower shift shaft' You have to turn the lower shift shaft clockwise until it locks. Then slide the foot down over the lower shift shaft with the foot facing forward.(don't forget the washer under the foot)

After re-reading, I think you have that part right.


In the lower case, there's a pocket that the lower shift cable 'slide' slides into. Check in there for junk that may have gotten packed in there over the years.

Lastly, the shift adjustment may just be out of whack.

Put the drive back on and disconnect the lower shift cable end from the lever. manually shift into forward/neutral/reverse. If everything is put together correctly in the drive you should get each gear. Test buy rotating the prop clockwise in forward gear so you get the dog clutch ratcheting. Neutral should spin freely both ways, reverse should ratchet the dog clutch by turning the prop counter-clockwise.

Tell us what you find.




OH! And I understand what your machinist did if he faced the dog gears because of rounding or chipping from the shift being out of adjustment.

 

[Bt Doctur]

Re: Shifting frustration

A worn shift spool will do the same thing,

 

[xltier]

Re: Shifting frustration

adjust your reverse throw with the slotted bolt at the end of the cable after u set the forward with the barrell adjuster.have someone turn the prop counter clock-wise while you push the cable in forward.u want 6 inches between the center of the adj barrell and the center of the hole on the end of the cable.then adjust for reverse the same way with the prop all the way turned in oppisite direction.cw.pull out all the way on cable and set it with the slotted adjuster.