Wrecked the Alpha drive?

[joenapier]

I dropped the lower and changed out the impeller and all went fine. Now...re-installing the lower unit may have sunk me.

I lined the lower unit and lifted it up. It slid all the way up to the mating surface - perfectly. I reached for the nuts and I let it slip down. Lifting it up again and I could only get it up to about an inch from mating. It was coming to a hard stop. Shaking and rattling it, I was able to coak it up another half inch, enough to attach a few nuts. Cranking on the wrench, I closed the gap. OK - now to start it up.

Uh-oh. I tried to shift out of forward and it would not budge. Right then I felt sure I had wrecked the dang thing.

I dropped the lower unti again. There was a washer, about 3/4 inch, on top of the splined shifter shaft. (Was it there before?). My cranking beveled and puckered that washer like a bullet went through it. What other damage might I have done up in the upper unit?

I'm going out now to try to install it the right way this time and see if I still have a shifter.

BTW - I have a Alpha Gen I. Its on an old Century Arabian that I am restoring. I'm your basic DIY'er - over my head and damn lucky to have this forum. I live in Charleston, SC.

Thanks a million...

 

[Fishermark]

Re: Wrecked the Alpha drive?

Did you damage it? Don't know. Yes, the washer is supposed to be there on the splined shaft. Sounds like it got dislodged and your "extra persuasion" bent it up. Put a new washer on and see what happens.

Just for future reference - if it isn't going together you need to find out what is binding instead of simply cranking it down.

 

[joenapier]

Re: Wrecked the Alpha drive?

I sure did "pursuade" it a bit too much.

Aside from the washer that looks like a cone, I also seem to have bent the shift receptacle in the upper unit that takes this shift shaft "foot" into it.

Now what do I do? I can't possibly get in there to bend it back down.

See picture. You can see I lack about 1/8 inch to mating the lower unit to the upper,and the shift mechanism won't connect fully when I do due to the bent u-shaped receptacle.

 

[Don S]

Re: Wrecked the Alpha drive?

If it's bent, replace it. They don't straghten up very well.
Put a new washer in, check your coupler alignment and you shouldn't need force to put it togehter.

 

[Bondo]

Re: Wrecked the Alpha drive?

I also seem to have bent the shift receptacle in the upper unit that takes this shift shaft "foot" into it.

Now what do I do? I can't possibly get in there to bend it back down.

Ayuh,... Replace it...

 

[Fishermark]

Re: Wrecked the Alpha drive?

the part you bent is called the intermediate shift shaft. It is easily replaced. You need to pull the upper unit off, then you can see it is simply held in with a cotter pin. While you have the upper off, as Don mentions you can check your alignment. It is also easier to assemble the lower and upper together before you install the complete outdrive back on the boat.

Here's a pic:

 

[joenapier]

Re: Wrecked the Alpha drive?

Thanks guys. Too bad I have more time than money. Even then, sometimes I lack sense too (cents, ha ha). I'm glad it looks like something I can do.

Hey FM, I see exactly what you mean and I can see the cotter pin inside under the upper unit. What about the receiving end of this foot? I can see it in the picture - looks like a small piece of u-shaped channel on the end of a shaft. Where do you get these pictures?

 

[joenapier]

Re: Wrecked the Alpha drive?

BTW - I did have the upper unit off just a few months ago to set alignment after I replaced the engine mounts. That was a chore jumping in and out of the boat several times before I got it dialed in.

Appreciate your help on this!

 

[Don S]

Re: Wrecked the Alpha drive?

Not sure why you want the pictures, you can get the upper shift shaft from your local Mercruiser dealer, or any online Merc dealer
You can also CLICK HERE and you can download the OEM manual. (It has pictures too)

 

[joenapier]

Re: Wrecked the Alpha drive?

Pictures are helpful - I can see how the shaft runs up, how it connects, and everything. Don't you find a picture helpful, DS?

Gosh, a merc dealer can get me the part? That's great news.

Anyway, I got it fixed last night and everything shifts just fine. I appreciate everyone that gave me some constructive information - thanks!