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  1. #1
    Seaman
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    Default 84 Merc 260 shift cable. whats that part and how do I replace

    Underneath the top section of my Alpha outdrive there is a metal tube that connects the shift cable to a threaded pin in the lower housing. I rotated the pin and it switches the unit from forward to reverse. When I push up no the tube one would expect it to connect to the shift cable, in my case if you find the "right" position rotating it .. it will connect otherwise if just spins freely. If I get it in the position where it connects how do I keep it there while installing the lower unit ? If not possible how do I replace the cable ? Can't find the R/R for this anywhere. Do I have to remove the upper half of the
    outdrive ? I went to West Marine and we found the correct shift cable but it doesn't look anything like what I am looking at under this upper-unit. No tube. no washer with cotter pin on the tube.

    Thanks
    OTG

  2. #2
    Honorary Moderator Emeritus Don S's Avatar
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Is this what you are looking at?


    Attached Images Attached Images
    Don S.


    Please, no PM's (Private Messages) regarding boat/engine problems.
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    Only forum/moderator issues will be answered in PM's.

  3. #3
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Haven't dug that deep yet. Here are two pictures of the parts. The tube hanging from the upper slides over the pin (gold ring on left of pic). Finally found my camera.

    OTG
    Attached Images Attached Images

  4. #4
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    there should be a stainless steel washer that goes on the shaft first, then install the lower
    NO PERSONAL QUESTIONS, THIS IS WHAT THE FORUM IS FOR.

  5. #5
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by Bt Doctur View Post
    there should be a stainless steel washer that goes on the shaft first, then install the lower
    Did that. Problem is when the "tube" is pushed upwards it does not always attach to the
    shift cable. Have to rotate the metal tube and push upwards before it eventually connects.

    Thinking the cable end is messed up.

    Thanks
    OTG

  6. #6
    Captain
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    That is your intermediate shift shaft. It does not attach directly to the shift cable, it slides into the coupler on the bottom of the upper shift shaft, which does "attach" to the cable. This is a illustration of the parts :http://www.mercruiserparts.com/Show_...c=BELL+HOUSING 23 is the shaft, 21 is the upper ss. It works this way: When you move your control handle the shift cable moves back and forth (back for F) and moves an arm attached to the upper ss. This rotates the ss (cw for F) and the rotation is transferred to the intermediate ss in the driveshaft housing and on to the lower ss in the gear housing. That movement slides the shift spool back and forth to engage either F N or R. The coupler at the bottom of the upper ss allows the two shafts to slide apart when you remove the entire drive. This is what you need to do: Shift the control handle to forward WOT. Turn the short splined shaft (lower ss) all the way clockwise, make sure the stainless steel washer is in place on top of the lower ss bushing (brass in photo), rotate the prop CCW until it locks and bungee it in place (you are now locked in F). Make sure the quad ring is in place in the oil passage, and slide the gear housing up into the driveshaft housing, making sure the top of the intermediate ss is pointed straight ahead when it slides over the lower ss, so that it matches the coupler on the upper ss. If you have to rotate the prop to get the driveshaft splines to slide in, rotate CCW only. Should fit in there quite nicely. Good luck.
    Terry
    87, 4WINNS H 190
    470/Alpha I

  7. #7
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by stonyloam View Post
    making sure the top of the intermediate ss is pointed straight ahead when it slides over the lower ss, so that it matches the coupler on the upper ss. If you have to rotate the prop to get the driveshaft splines to slide in, rotate CCW only. Should fit in there quite nicely. Good luck.
    This is where I messed up. I was thinking the top of the intermediate SS was internally splined like the bottom. This is why it only "connected" at certain rotated positions.
    Have to read it again and look up into the cavity to see what pointed straight ahead means. The parts breakdown shows it as being pretty obvious.
    Thanks so much for the information. Wasn't looking forward to replacing the cable especially when it isn't necessary.

    Thanks again
    OTG

  8. #8
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by otgdy View Post
    Have to read it again and look up into the cavity to see what pointed straight ahead means.
    Look at Ziggy's photo. That is NOT straight ahead LOL. If it were rotated 1 click to the left it would be.
    Terry
    87, 4WINNS H 190
    470/Alpha I

  9. #9
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by stonyloam View Post
    Look at Ziggy's photo. That is NOT straight ahead LOL. If it were rotated 1 click to the left it would be.
    Finally found the parts shown in Don's picture. That's exactly how it looks from a weird angle I might add. That is definitely where I screwed up originally. I set the shift linkage to get the two pieces facing straight forward but could only get it the way Ziggy's picture has it, one click off. There is no more adjustment in the cable for a true
    straight ahead so I am going to try it this way after getting some replacement gaskets.

    There is an adjustment tool that they sell for this shift linkage ? Do I need it ?

    Thanks
    OTG

  10. #10
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by Don S View Post
    Is this what you are looking at?


    Well I got the pump rebuilt and now I am setting connecting the upper/lower units. My shift shaft looks exactly like ziggys above (one click off to the right). I disconnected the cable at the engine and it is bottomed out. Translation I can not get the cable to point straight back to match the intermediate shaft. Tried to move the shift the intermediate shaft over one notch on the pin but it will not slide together.

    How do I get them to align ?

    Thanks
    OTG

  11. #11
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by otgdy View Post
    How do I get them to align ?
    You need to rotate the intermediate ss all the way clockwise. Turn the prop ccw until it locks. Pull the intermediate ss up off of the splined lower ss, and rotate it clockwise so that it points straight ahead and push it back onto the lower ss. Make sure the control handle is WOT forward and the connection on the bottom of the upper ss is pointing straight ahead. She should go together.
    Terry
    87, 4WINNS H 190
    470/Alpha I

  12. #12
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by stonyloam View Post
    You need to rotate the intermediate ss all the way clockwise. Turn the prop ccw until it locks. Pull the intermediate ss up off of the splined lower ss, and rotate it clockwise so that it points straight ahead and push it back onto the lower ss. Make sure the control handle is WOT forward and the connection on the bottom of the upper ss is pointing straight ahead. She should go together.
    I have the lower ss straight ahead and the unit is locked in forward. Have a bungee holding the propeller. the problem is the top "female receiver" is one notch to the right like in the picture and I can not get it to point straight back to match the lower SS.
    Am I misunderstanding something ?

    Thanks
    OTG

  13. #13
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    The control handle is all the way forward?
    Terry
    87, 4WINNS H 190
    470/Alpha I

  14. #14
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by stonyloam View Post
    The control handle is all the way forward?
    Yes even disconnected the cables from the engine linkage and moved the adjustments to the stops and I still cant force the recepticle straight forward.

  15. #15
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by otgdy View Post
    Yes even disconnected the cables from the engine linkage and moved the adjustments to the stops and I still cant force the recepticle straight forward.
    Did you push the cable or pull it? You have to push to go into forward.
    Terry
    87, 4WINNS H 190
    470/Alpha I

  16. #16
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by stonyloam View Post
    Did you push the cable or pull it? You have to push to go into forward.
    I pushed the cable until it bottomed out. Even rotated the adjuster so it would allow all of the available cable to extend towards the outdrive. Still not aligning. Interesting that this was functional prior to impeller and shifter replacement. Figure that.

    OTG

  17. #17
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Only one thing left to check. On the end of the shift cable is the shift slide looks like this http://www.amazon.com/Sierra-Interna.../dp/B0000AYZ60. There are two arms on the slide that capture a little wheel on top of the lever on the upper shift shaft. What can happen is that the wheel slips out from between the arms and is either in front or behind them, in your case in front. When you shift to forward the slide moves back, but since the wheel is not between the arms it does not move. Also when you try turn your shoe on the bottom clockwise the wheel hits the front arm and will go no further. You need to slide the outdrive back far enough to correct the situation and make sure the wheel is between the arms, should not have to take the outdrive all the way off. Then put in forward lock the prop.... you know the drill. Good luck.
    Terry
    87, 4WINNS H 190
    470/Alpha I

  18. #18
    Rear Admiral Fishermark's Avatar
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    I would agree that it sounds like the shift slide is out of place. You really need to invest in the orange tool pictured here. It costs a dollar or two - and is well worth it! It holds the shift slide in place while you put the outdrive back on.


  19. #19
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by Fishermark View Post
    I would agree that it sounds like the shift slide is out of place. You really need to invest in the orange tool pictured here. It costs a dollar or two - and is well worth it! It holds the shift slide in place while you put the outdrive back on.

    Want to thank you for the information. Now I progress into the world of the inards.
    Can you tell me where this shift slide lives in this photo ? I assume the square peg that the tool is holding is the shift shaft ? Do you recommend that I hook a cherry picker up to the outdrive or is it obvious that it is about to fall on my head ? I will check around for the orange tool. Hopefully WM will have it. Any other tools I may need ?
    Thanks again. This weekend should see 100+ degree weather. Perfect for this task.
    OTG

  20. #20
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    So you have not removed the upper? I thought you did. Anyway the upper shift shaft is the shaft in the center, the arm is on top and the slide is on the right with the orange thing on it.
    Terry
    87, 4WINNS H 190
    470/Alpha I

  21. #21
    Rear Admiral Fishermark's Avatar
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by stonyloam View Post
    So you have not removed the upper? I thought you did.
    I guess I did not read it well enough either... I thought you had the entire outdrive off. You can pull it off without a cherry picker - the upper is not very heavy. I would suggest pulling it so you can check the condition of the bearing, check the alignment, etc. It is also easier to put back together on the bench - then put the entire outdrive back on.

  22. #22
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Quote Originally Posted by Fishermark View Post
    I guess I did not read it well enough either... I thought you had the entire outdrive off. You can pull it off without a cherry picker - the upper is not very heavy. I would suggest pulling it so you can check the condition of the bearing, check the alignment, etc. It is also easier to put back together on the bench - then put the entire outdrive back on.
    Doing it on a bench sounds like a good idea. At least it will be cooler inside. I would feel better checking everything prior to reinstalling it. The only thing that gives me pause is "checking the alignment etc". Am I opening a can of worms ? Can you tell me or direct me to some documents that describe what I am aligning, checking etc? Knowing me I will probably replace everything in there while I have it torn down. Now you know why it is taking me 2 years to get this in the water. Isn't there a special alignment tool for this ? I seem to remember reading about a Merc part for engine alignment ?

    Thanks again
    OTG

  23. #23
    Rear Admiral Fishermark's Avatar
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    At the top of the page there is a section with "must have information for DIY" - there is a good post there on engine alignment. There is some other good general information. I suggest you do some reading there. Here's the post on engine alignment.

  24. #24
    Seaman
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    Default Re: 84 Merc 260 shift cable. whats that part and how do I replace

    Well I pulled the outdrive off and the shift shaft looked ok initially. I removed the intermediate shaft and found the locking pin had almost completely backed out.
    I removed the shaft , cleaned it up and reinstalled it. Looks good now.. well at least
    it is pointing forward like it should.

    Unfortunately the bellows (that the drive shaft is in) is full of sludge and the universal joints are all rusted. Cleaned out the area, regreased the U-Joints (which feel ok when twisting with my hands), regreased the inner bearing ( which too feels good spins well) and interestingly enough everything in there looks brand new. Flexed the bellows and it is flexible and doesn't have any junk on it. The only thing I found suspicious was the white powder around the 1-2 in outlet at the 8:00 position. Looks like it leaked into the bellows. The 6in (guess) round seal that seals the upper unit to the gimbal housing fell out when I pulled the upper unit. Found some brown glue residue where the seals are which obviously didn't hold. Thinking the failure of these two seals was the problem.
    Sorry to go on and on .. maybe this should be another thread or is there another thread I should be reading regarding this ? Wondering if I should bite the bullet and replace everything in there or is there a way to verify whats there is still good.

    Thanks again for all your help.
    OTG

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