Won't engage in gear. Had shifting problems prior.

[ngk0325]

Hello all. I'm new to this. I have searched many posts to try to find a similar issue, but cannot seem to find an exact fit.

I have a 89 Mercruiser 350 Magnum Alpha One I/O. Prior (and leading up to) my current issue, I had shifting problems. On land with muffs, everything would work fine but when I got into the water, It was very difficult to shift into neutral after being in gear. I would have to go from forward and when I brought the throttle back it would go directly into reverse and then I could try to manage to get it into gear. I was at the point of lubricating the shift cables (which I did) with WD40 and I was out testing this. It seemed to be a little bit better, but not normal.

When I was out, however, I was taking a friend on the wakeboard and I went to kick it into forward and nothing. Engine was just reving. While in the water I tried using my oar (not the best idea, but I figured I would try) to press on the prop and hope it was just stuck for some stupid reason. It seemed to be locked up when I pushed it one way while in forward gear. It seemed like it was just reving the engine. I did not get a chance to try it once I got home (I was frustrated).

I'm an fair mechanic (not by trade) but have gotten very acquainted with this engine the past few years, so I will try to do most repairs. I have an extra lower unit (which is my guess as to the problem). I do have the repair manual (online edition). An uneducated guess on my part is that the gear housing did not have enough gear lube in it or that there may be water in there (have not drained it to check yet.

Any ideas would be great!! Thanks.

 

[Haut Medoc]

Re: Won't engage in gear. Had shifting problems prior.

Welcome to iboats.....
You need to replace your lower shift cable.....
Pull the drive.....
Turn the shift shaft clockwise & the prop ccw & it should lock....
Turn the shift shaftt ccw & the prop cw & it should lock....
Put the shift shaft between these two points & it should freewheel either way.....
Drain the gear lube from the drive & inspect the color, lube the u joints while you are at it.....​

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

how hard is it to replace the lower shift cable? Price? Also, what kind of lube do I use for the u joints?

 

[Haut Medoc]

Re: Won't engage in gear. Had shifting problems prior.

http://www-alt.mercurymarine.com/mnetdata/SERVICE/CRUISER/Servmanl/6/6covr3.pdf
Here is the manual for your drive....
It outlines how to change your lower shift cable.......
It would be wise to replace the u joint bellows at this time if they haven't been done in the last five years......

 

[Haut Medoc]

Re: Won't engage in gear. Had shifting problems prior.

how hard is it to replace the lower shift cable? Price? Also, what kind of lube do I use for the u joints?

The cable is not that hard to replace....
It requires two special tools that are less than $20 each....
The cable is $50-75, depending if you go merc or aftermarket.....
It should take two hours for a pro to do it, so figure that at your local rates....
The u joint bellows are considerably more expensive to install if done at a shop......
The reason I say to check/replace the bellows is that it is the next step in the process after the cable.....
Read the manual to see if it is something that you are capable of tackling.....
Mercruiser makes a specific product called, u joint & gimbal bearing grease.....

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

AH! Ok So I took my boat to the local mechanic. He said that the spline is stripped and the coupler needs to be replaced. I told him that I thought it could be the lower shift cable. He said he doesn't have a hoist and referred me to another mechanic who could do the job. He said that engine needs to be taken out and replace the spline and the coupler. Any idea how much $$ this might be? He showed me with a flashlight where it was stripped. The shaft on the outdrive looked a little stripped...but would that have to be replaced as well? I'm guessing that this is also the reason I was having trouble shifting....? He charged me $75 to pop off the outdrive. Hopefully I won't have to sink too much more money into this.

 

[Bondo]

Re: Won't engage in gear. Had shifting problems prior.

shaft on the outdrive looked a little stripped...but would that have to be replaced as well? I'm guessing that this is also the reason I was having trouble shifting....?

Ayuh,....

That Shaft will need to be Replaced,+ the Alignment Fixed......

You probably Still need a new Lower Shift Cable,...
And,....
I'm guessing there be More Issues uncovered when the motor is pulled....
The Alignment shifted for a Reason,..... Rotten Transoms are a very Common 1.....

 

[danond]

Re: Won't engage in gear. Had shifting problems prior.

Hopefully I won't have to sink too much more money into this.

You will. Welcome to boating!

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

any guess as to $$ for the coupler and shaft?

 

[NYJim]

Re: Won't engage in gear. Had shifting problems prior.

I have a 89 merc I/O 5.0. had similar issue. I had the lower unit rebuit last year for $1100. i reinstalled it with permatex on the gasket. not good for salt water. this year it started to shift hard, then not at all. seems the permatex gave way and let salt water in. another $1100 bucks to rebuild it. NOT HAPPY. anyway I thought it was the shift cable as well. let the mechanic or you discount the shift cable from the engine and see how it moves. my bet it will cost you aroud 1100 for the rebuild.

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

yeah but the coupler and shaft is under the engine. any guess as to the price of that?

 

[NYJim]

Re: Won't engage in gear. Had shifting problems prior.

Sorry Nick, no clue on that

 

[Uraijit]

Re: Won't engage in gear. Had shifting problems prior.

The parts alone are going to run from around $300-$400 (depending on your mechanic's markup). You can buy them online for about $275 for the coupler and shaft (in a set).

After the parts, you get to start thinking about paying the guy to do it. At $75-$100/hr, it's gonna add up quick!

If you're mechanically inclined, you can save big bucks by doing the work yourself.

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

OK-

Went to another mechanic today (here's the damage so far)

After a quick check (he's calling me tomorrow after he takes everything apart)

Bellows and lower shift cable
Engine coupler and tail shaft
water pump
yoke?
seals
POSSIBLE:
sked repair + new cone repair

Rough estimate: $1500-$1800 (how's this price sound??)

Bought boat for $5000
Worth fixing?
I posted it on craig's list today... see if I can find someone who needs a fixer-uper

THANKS FOR ALL YOUR HELP

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

WOW. Just got a .pdf invoice. Anyone want to take a look? $3223.80. Anyone think I can do some of this work myself?

Tell me if you want the pdf and I'll send it to you. PLEASE HELP!!!

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

Bellows kit - 205
merc shift cable (lower I assume) - 87
Transom bushing kit - 38.50
engine coupler with tailshaft - 330
outdrive oil - 30
impeller kit with housing - 50
upper driveshaft seal - 12
yoke seal and assy - 114
shift shaft bushing - 16.5


Total Labor 19 x 75 = 1425

Optional Stuff

skeg repair 175
trim limit and sender (to make gauge work) 95
nose cone - 75
prop repair - 185
outdrive u-joint- 106
merc center socket 50

Labor 2 x 75 = 150


Anyone think I can do any of this? 3223 is steep. I only paid about 5k for the boat....

 

[Limited-Time]

Re: Won't engage in gear. Had shifting problems prior.

If your mechanically inclined, and have basic tools and are willing to invest in tool you'll need..............it's all doable................and not that hard.....................but for a first timer it will be time consuming.

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

I don't have a hoist, but my uncle has a backhoe that he said we could use as a hoist. Where is a good place for parts? How many hours would you estimate? about 20?

 

[Limited-Time]

Re: Won't engage in gear. Had shifting problems prior.

20 hrs min...............as for the hoist.............I'd beg, borrow, or rent a chain fall...........you can use the backhoe for a lifting point, and to move the engine around after removal, and for initial positioning prior to instillation.................but I'd use the CF for control sake...............in and out.

 

[ngk0325]

Re: Won't engage in gear. Had shifting problems prior.

what's the best place for parts? Also, does anyone have a 'full' service manual as to this job? or even just taking the engine out?

I tried sterndrive.info, but if somewhere else is better i'll do that...