Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

[dtescher]

Volvo Penta 4.3GL PLKD SX-C1 1.85 #4112030094. There's a hard clunk when shifting forward or reverse. I changed the gear oil and checked for metal shavings. None found. That didn't help the problem. Checked gap under large nut at the top
of upper gear housing, 0.12 reading. Checked cables for kinks etc. Adjusted shift cable per manual. Still no better. What else to check or should I just take it to a certified Volvo Penta shop?

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

What's the idle rpm in neutral?

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

600-650Rpm

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Do you have SS prop and is the boat in or out of the water?

under large nut at the top of upper gear housing, 0.12 reading.

is that metric or inches?

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Aluminum prop. And it's out of the water.

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Did you catch my second question above?

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Just saw it. That's inches.

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

If that's inches, you found your problem. You should have .002 to .010. The gap of 1 to 3 pieces of paper. You have an eighth of an inch. How or why I can't say without taking it apart and looking.

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Ok. Thanks Don S. I'll check it out. By the way, is it difficult to take upper gear housing apart to check it. What should I be looking for?
And how hard is it to re-shim? If that's what it needs.

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Correction!!! I just checked feeler gauge and it's 0.12mm. Sorry about the confusion.

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Ok. Thanks Don S. I'll check it out. By the way, is it difficult to take upper gear housing apart to check it. What should I be looking for?
And how hard is it to re-shim? If that's what it needs.

Without the special tools, it's impossible.

Even with the special tools they can be a job to get shimmed right, and have the right gear pattern and preloads all at the same time.
I assume you have the OEM manual and have looked at the procedures?

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Correction!!! I just checked feeler gauge and it's 0.12mm. Sorry about the confusion.

Then you are fine,

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Yes, I have the manual. Good point. I wouldn't be able to do that. OK, but it still clunks. What to check next?

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Or just take it in?

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Think your getting ahead of yourself, what's it sound like in the water when you shift.

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Clunk!!! And out of the water it's a loud CLANK!!! Can't tell if it's coming from upper or lower gear housing. And it's getting worse. No
water till I figure it out.

 

[Don S]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Get a shop tach, or a timing light with a tach built in and verify the idle speed.

How did you test the top nut gap? You had the upper off the lower didn't you and pushed up on the vertical shaft and down on the upper bearing didn't you?

How did the ujoints feel?

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

I'll verify the idle. And, no I didn't have the upper off the lower. Just checked the nut with the feeler gauge from the top. I'm new to all this. So, I didn't know I was supposed to take the upper off the lower. And I haven't check the u-joints yet. Thanks Don S. As usual you are a wealth of information. I will try to get the upper off the lower and check the u-joints.

 

[dtescher]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Thanks Don S. The idle is all over the place. When it's at 600RPM it shifts perfectly(in water test). Anything above that and it clunks. Should I adjust the cable to verify a slight pre-load on the carb? And, how to best approach adjustment of throttle cable?

 

[Levinz11]

Re: Volvo Penta 4.3 GL Loud Clunk When Put In Gear Fwd Or Rev

Thanks Don S. The idle is all over the place. When it's at 600RPM it shifts perfectly(in water test). Anything above that and it clunks. Should I adjust the cable to verify a slight pre-load on the carb? And, how to best approach adjustment of throttle cable?

What does that mean? The idle is fluctuating on its own?