Shifting problem, need some help please!

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
I haven't been boating but for 3 seasons. I knew nothing about a boat when I got her, but I know quite a bit now. I do have a background in engine, electrical, and moderate mechanics. I graduated from MMI(motorcyle part, not Marine). Ive had 4 years Auto Tech in school, and worked on my own stuff all my life... I Just dont know ANYTHING boat specific (except what I've learned in the last couple years).

Last year was the first year I did the whole 4th of July on the lake. It was great (except for my problems with the boat but we havent got their yet). If you want the details read the LONG story. Otherwise I placed the key bits, or at least what I think is key in the SHORT story part. I know the long story is, well.... LONG but thats everything I can remember. I appreciate you taking the time to read this!

~~~Long Detailed story~~~
Somewhere around April of last year I started noticing that when I went into reverse, if I put a moderate load on the throttle, the stern would "kick" like its popping out of gear. It only did it when I gas'd it pretty good so I didn't rush home to grab the wrenches. After about 2 more times on the lake, I started really loosing reverse, but again, It was only reverse. I had paddles if I needed to go backwards. Now please don't judge me at this point, I want you to understand that maybe 2 weeks prior, I had just replaced one of the hydraulic lines for the trim, and it was a nightmare getting the stern back on by myself. I'm not the type to let something just ware slap out before I fix it, BUT I assumed it was in fact the shift cable and like a noob I put if off. Well finally it started effecting forward. So I decided I had to get something done. I knew I was going to pay someone to fix it to save me the headache of messing with that stern, but it was 35 days away from this july 4th trip I had been planning since the year before.

~~~RANT on MANN MARINE!!! Next paragraph is the outcome.
I called around to get estimates, and found a place called Mann Marine in Kernersville, NC. I told them I knew it was 35 days away, But I wanted to be sure that under no circumstances would they need to keep the boat until the weekend of the 4th. I was promised numerous times that the boat would be back to me, in my garage, no later than 2 weeks before, At worst they would keep it for 2 weeks. We also agreed on a flat price for the parts, taxes, and shop labor for the job. I agreed, so I took it to them. I'm not the type to rush or bother anyone when something has been agreed to so I didn't call them until the end of the second week. At this time they informed me that they had been behind, and hadn't even looked at my boat. They told me to give them 1 more week and they would make sure it was finished. A week later the same story. I told them I was just going to come get the boat, and the guy said he was really really sorry, he knew he had promised me the boat back last week but please just give him one more chance. 1 more week and he guaranteed it would be done, and he would even tune the carb for me for free for my trouble! Ok so another week goes by, I give them a call, and the guy said that he had just pulled it into the garage, it was going to be started first thing in the morning. I was a little pissed, but since it was finally getting done, whats another day. I agreed and got off the phone. Later that evening I started thinking, something just don't sound right, so I jumped in my truck, and made the hour long journey to see if it was really inside. Guys the boat hadn't moved since I parked it! I drove back home and waited for the next day to call again. The next day I called and questioned the guy about him "just pulling it in" and "it would be looked at first thing in the morning" and he said that he had to pull it back out for the night. I asked him then what was the point of pulling it in? excuse after excuse. I told him to forget it I was on the way to pick it up. He acted like he didn't care, but people I didn't make it 15 minutes down the road before he called me (for the first time ever) and actually had looked at my boat. He must of ran outside, climbed in, and looked around... But by the way he had talked I could tell that he at least had LOOKED at my linkages. Anyways he said to let him work on it, he would call me in a couple hours when it was finished. Again, a lie. The next morning was July 3rd, 1 day from the big event, and 2 weeks past when it was supposed to be back home. So again I called him and said have it ready, I was on the way fixed or not it was going with me. He said to wait he was working on it right then. I said NO and hung up. By the time I got there I didn't see my boat. I went in and asked if it was finally being worked on, and a different guy said it had been taken to the lake to be test rode. I decided to hang out in the lobby until it got back. It was actually funny because while I was sitting there a guy walked in the shop asking why his boat was a week behind schedule. He got told the same story I was, but he actually told them to get his boat he was taking it somewhere else. His boat was actually in the garage area. They also got a call, and although I only heard the business side I came to the conclusion it was the same kinda thing. "Hello.... oh hello soandso....yea we are trying to get a look at it now... its been a hecktik week around here...I know, I know, but I promise it wont be much longer...(insert 5 minutes of excuses)... well I can't stop you from coming to get it but if you'll be just a little more patience...hello?...Hello? I couldn't help but grin. At least I wasn't the only one who was getting screwed! Anyways I looked around the shop, and waited for about 45 minutes, and finally here come my boat.

Once he parked my boat, the guy acted like we were best friends, but procedded to tell me that the shift interrupt switch wasn't working. A micro switch that allows the linkage to kill the engine long enough to shift to and from gears, and this was most likely why the cable had stretched to begin with. Someone had forced it. I said I would keep that in mind, and would fix it at home. He told me it was a safety issue, and the boat couldn't leave the shop until it was fixed. I said we would see about that. I told him if he didn't un-hitch my boat from his truck I would do it myself, and if he gave me any more trouble I would call the police. He said to let him go talk to his manager to see if he could release the boat in that condition. Sure enough the boat was released. I had to sign a waiver eliminating the shops responsibility if something happened, but I would die before this shop got another second on my boat. I went inside to pay, and the bill was 80 bucks more than we agreed. I asked him why, and he said it took longer than expected. I told him that didn't matter, I wasn't going to pay any labor except what the shop book called for on that job (When you work flat rate you have an alloted time to do a job. Any longer and the tech loses money, the idea is to be quicker and start on another job. Thats how most dealership mechanics get their pay). This guy knew I was a mechanic too, I don't know why he thought he could screw me over on the tab. Long story short, I paid exactly what I agreed to begin with, hooked up my boat, and drove off looking in the mirror PRAYING the shop would explode. :mad:

So that's the deal with this HORRIBLE, WRETCHED, SAD EXCUSE FOR A MARINA. Skip down to "Issue"


~~~Short story~~~
I was told my shift interrupt switch is bad by a very un-reliable source (MANN MARINE, NC, BEWARE!!!)This was the diagnosis after having them replace my shift cables. I would have done it myself but I had JUST put the stern back on from a previous repair, and did NOT want to wrestle that thing again in such a short time. They actually tried to force me to let them make the repairs, but I refused and threatened to get the law involved if they didn't release my boat. If you want the whole story, just read above.



~~~Issue~~~
All I know is that I cannot shift into neutral, and shifting out of neutral gives a slight "Clunk" into gear (which I was told on here last season that was normal).(only when in the lake. when its muffed*, it either seems to work, or at least doesn't give so much trouble)

Anyways, it makes it impossible coming into the dock smoothly, or in heavy traffic areas. I actually have to kill the motor with the key to put it into neutral, crank it back up, just to go into the opposite gear. I've heard that on this model OMC that the motor idles only on 3 cylinders, and doesn't go into using all 4 until once its in gear. And that helps it shift. That tid bit is also from a guy who swears my motor is an Iron Duke, although Im fairly sure Iron Duke is only Pontiac. Either way I figured his tid bit was worth mentioning!

I have a multimeter, plenty of tools, camera, whatever you need. I just need someone to help me figure out where the problem is. I assume that if it is in fact a switch I can check it with my meter, but I have to know specs and what switch to check.

Guys can you find it in your heart to help me? Shoot me some resources, talk me threw it. I'm willing to do the work, just need a little expert guidance. I promise in return when I get all expert and stuff I will pay it forward to the next new kid on the block.

Thanks again guys
Ive got to figure this out, hopefully you guys will help.
 

a70eliminator

Captain
Joined
Sep 9, 2007
Messages
3,762
Re: Shifting problem, need some help please!

It more than likely is the shift interupt switch, it's job is to stumble the engine mometarily and precisely when shifting out of gear, a new lower shift cable is right around 80 bucks, I highly recomend it, the shift interupt switch I haven't had to replace so don't know how much they are. Your idle speed must be no more than the spec of I think 550 in gear, high idle can cause your shifting out of gear problem too, the interrupt switch is nothing more than a normally open microswitch easily checked with your ohm meter.
 

Joshua Nichols

Lieutenant
Joined
Jun 29, 2009
Messages
1,431
Re: Shifting problem, need some help please!

Wow what a nightmare....
Sounds like the ESA to me too.. You do need to make sure your idle is correct like said above.. The ESA is super gravy part change(Just changed one a few months ago)

BTW the outdrive shouldn't be that tough to get on.. It is heavy, but that's it.. Did you do a correct alignment to the engine before you installed the drive? If not.. I recommend ya do it..
 

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

Yea heavy, and wiggling the thing to get the shaft to go in is a nightmare. Being by yourself doesn't help at all.

Yes I lined the thing up, however I can't say if they did or didn't at the "so called shop"

Can anyone help with specs?

Thanks guys
 

HT32BSX115

Supreme Mariner
Joined
Dec 8, 2005
Messages
10,083
Re: Shifting problem, need some help please!

Yea heavy, and wiggling the thing to get the shaft to go in is a nightmare. Being by yourself doesn't help at all.

Yes I lined the thing up, however I can't say if they did or didn't at the "so called shop"

Can anyone help with specs?

Thanks guys

Howdy,


At this point, no one here can probably successfully "walk you through" a lower shift cable adjustment. It's fairly complicated to do using the service manual.

If you want to fix it yourself, you NEED to get an OEM OMC service manual (Not Seloc/Clymer etc......use those next winter to start your wood stove;);)!!)

Also, take a look at the following link. It's pretty helpful too.... http://www.hastings.org/~stuart/cobra/

MAN I'm glad I got rid o'my Cobra!


Good luck....


Rick
 

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

Howdy,


At this point, no one here can probably successfully "walk you through" a lower shift cable adjustment. It's fairly complicated to do using the service manual.

If you want to fix it yourself, you NEED to get an OEM OMC service manual (Not Seloc/Clymer etc......use those next winter to start your wood stove;);)!!)

Also, take a look at the following link. It's pretty helpful too.... http://www.hastings.org/~stuart/cobra/

MAN I'm glad I got rid o'my Cobra!


Good luck....


Rick

guys??? are you not reading my OP?

The cable was done at the "so called marina"

Now im trying to diagnose the ESA
 

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

Ok here is an update...

Look at this picture....
IMG00131-20110510-1601.jpg




100$ says the guy at the marina broke off the little roller that the claw uses to activate the switch!!!



Ok now for the testing. According to this site...
http://www.marineengine.com/boat-forum/showthread.php?293383-OMC-Cobra-ESA-switches

"The interrupt is a NO (normally open) switch and the overstroke is a NC (normally closed)."

However according to my testing this is backwards. Here are the readings from my continuity testing...
ESA.jpg



Are my switches bad? Personally I believe that the link above is incorrect, However I'll let you be the judge. Normally when a switch is bad, a NO switch will be open all the time, and a NC switch will be closed all the time.

Anyways, what do you guys think?
 

HT32BSX115

Supreme Mariner
Joined
Dec 8, 2005
Messages
10,083
Re: Shifting problem, need some help please!

guys??? are you not reading my OP?

The cable was done at the "so called marina"

Now im trying to diagnose the ESA

It doesn't mean they did it right though.

Do not attempt to do any adjustment/testing without doing it in the water...........

You cannot make the ESA activate unless the drive is IN GEAR, and the prop is IN THE WATER. (I.E. under load)
 

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

Can anyone confirm or deny the switch is working like it should?

I get that the prop needs to have some "friction" for the ESA to work, however I can tell you I already know it isn't. It does not shift out of gear in the water.

I know that since the tab is broken off, that the claw isn't going to activate the ESA anyways at this point, but I want to make sure the switch itself is testing OK. That way the next time I go to the water, I know that the switch is NOT the problem.

If the switch IS functioning correctly, I can either manually trip the ESA, or repair it, and continue testing, but knowing that the switch is working is key in being able to go to the next step in diagnoses.

As far as adjustment, everything Ive read says you have to adjust it "dry" with the stern off, but lets test one thing at a time.

Judging by the readings from the multimeter, are the 2 switches good? I would assume so, however like I said before the documentation Ive read says they are backwards.


~~~EDIT
BTW, Even If I'm out of water, If I manually trip the ESA will I be able to tell that its working by the engine stumbling? If Im not mistaken, I tried that at the end of last season before I winterized the boat, and activating that switch by hand did nothing.
 

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

Ok I tested the plug going to the 2 switches, and BOTH lines in (the other 2 wires are just a jumper)are showing ~12v

I also tried manually activating the switches. If I have understood correctly, the ESA will not work unless the Overstroke is already activated. So I would hold the overstroke button in, and hit the ESA. As far as I could tell nothing happened. I performed these test in neutral thinking that by activating the Overstroke would trick it into thinking the boat was in fact in gear.

Is there something I'm missing? Am I just totally doing this wrong?

Help!

Thanks again
 

Xesvuli420

Petty Officer 2nd Class
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Messages
144
Re: Shifting problem, need some help please!

BTW
Ive been doing ALOT of reading, and one thing Ive found is that it seems my idle is way to high. I idle "dry" (according to the gauge) at between 1000-1100rpm. The motor doesn't sound like its racing, but I thought you guys should know.
 

RIDEPATE

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Messages
324
Re: Shifting problem, need some help please!

I think if you overstroked and esa'd, it would kill the motor. On the shift-plate it's just momentary, but manauling it should stop the motor dead I would think??
 

HT32BSX115

Supreme Mariner
Joined
Dec 8, 2005
Messages
10,083
Re: Shifting problem, need some help please!

BTW
Ive been doing ALOT of reading, and one thing Ive found is that it seems my idle is way to high. I idle "dry" (according to the gauge) at between 1000-1100rpm. The motor doesn't sound like its racing, but I thought you guys should know.

You must not be referring to the OMC service manual....... 1000-1100RPM (if your tach is right) is WAY TOO HIGH.

It should be around 600 RPM. the higher you go, the more damage you cause to the dog-clutches during shifting...... It also takes far more lower shift cable pressure (or tension) to get it out of gear!

The ESA may not reduce the torque enough to get it out of gear easily.....

Also, you should be able to activate the ESA by simply moving the "Shift Actuator" #37 in the pic below.
shift.png



If the ESA is NOT activating manually, either the switches are not working right (or a wiring problem) or the ESA is defective.

I gave the buyer my OMC service manual when I sold my Cobra...... so I can't refer to it......but I seem to remember a procedure for testing the ESA in the manual.
 

Joshua Nichols

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Messages
1,431
Re: Shifting problem, need some help please!

Turn the idle down... Then go try the switch with your finger.. You will never notice the stumble with it running that fast...
 

Xesvuli420

Petty Officer 2nd Class
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Messages
144
Re: Shifting problem, need some help please!

You must not be referring to the OMC service manual....... 1000-1100RPM (if your tach is right) is WAY TOO HIGH.

I wasn't saying I had it set correctly, lol I was saying that according to everything Ive read, my idle is set incorrectly.

The ESA may not reduce the torque enough to get it out of gear easily.....

Also, you should be able to activate the ESA by simply moving the "Shift Actuator" #37 in the pic below.
shift.png



If the ESA is NOT activating manually, either the switches are not working right (or a wiring problem) or the ESA is defective.

I agree, however would I beable to hear a drop in idle if I activated the switch? I understand it may not be enough for proper shifting, BUT would i hear a change?

I gave the buyer my OMC service manual when I sold my Cobra...... so I can't refer to it......but I seem to remember a procedure for testing the ESA in the manual.

I do have a PDF of some brand manual, but Im not sure which brand (OEM, Clymer, etc)

I couldn't find any testing procedures whatsoever on the ESA with this one.

Thanks for your help... I believe I'm going to have to do some work on the carb to allow me to get down to ~600rpm. Who knows, my tach could be off. Like I said it doesn't "sound" like 1100rpm, but who knows. I don't have a shop external tach to hook up and see

Let me go tinker, if I get any results I will post back.

Thanks guys
 

Xesvuli420

Petty Officer 2nd Class
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Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

I could not get the idle down. The idle screw was already backed all the way out where it didn't contact the plate.

I tried messing around with the air screws, and timing, and could not get it down any past 1000.



.
 

Ronen

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May 13, 2011
Messages
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Re: Shifting problem, need some help please!

As a new boater, I just purchased 89' Grady white with OMC v8 ford engine 205. I fired up the boat and when I engage in gear the engine shout down. Since I am new to this, I'm not sure if the cause for the problem was due to hight RPM/idle at neutral position going to gear? Or the causes could be old cable, or shift switch or other issue? Please advise

Thanks
 

Joshua Nichols

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Messages
1,431
Re: Shifting problem, need some help please!

I could not get the idle down. The idle screw was already backed all the way out where it didn't contact the plate.

I tried messing around with the air screws, and timing, and could not get it down any past 1000.




.

That doesn't sound good to me at all.. Could be apart of your problem
 

Xesvuli420

Petty Officer 2nd Class
Joined
Sep 20, 2009
Messages
144
Re: Shifting problem, need some help please!

So now what? What can I check to see why the idle is so high?
 
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