1967 Big Twin 40 won't go into forward gear.

[Fredrunabout]

I tried searching the forum for this topic but can't find the exact situation. I have a 1967 Johnson Big Twin 40 hp. I had the lower end unit replaced last fall with a brand new water pump. I just put it in the water for the first time and it won't go into forward gear. Reverse and neutral are okay. I can disconnect the cable and manually pull the lever down and get it into forward gear but it won't stay when I let go. I tried adjusting the cable but no luck, it just doesn't pull it down far enough to get into forward gear. In a previous post with a similar issue but different engine, someone replied by saying the drive rod in the lower unit may need adjustment, but there were no details. I could bring it back to the shop that did the initial repairs, but that may take a long time. Just wondering if it is something I could do.

 

[interalian]

I'm going to assume there were no problems with the gearcase when you took it in last fall? If it were my shop, I would prioritize a re-do if a customer had a new problem after a repair I did.

 

[lindy46]

On the leg of the motor (starboard side) there is a little cover held on by two screws. Remove that cover. Underneath will be another cover which also needs to be removed. Once both covers are off, you can see the shift rod linkage inside. Both the upper and lower shift rods must be secure in the brass coupling which joins them together. Bolts hold the rods into the coupling. Manually shift the motor and see what happens. Shifting into forward pulls the rod up, and if one of the coupling bolts is missing or stripped, the motor won't shift properly. Make sure one of the rods is not pulling out of the coupling when you shift into forward. If all looks good there, report back and we'll move on from there.

 

[racerone]

There is no adjustment at that coupler.---------You need to check that the notches on both upper and lower shift rod line up with the holes in the coupler.----Only then can the bolts be carefully installed.-----And I agree , visit the party that did the work.

 

[Fredrunabout]

Thanks guys, sounds like a reasonable quick check at least. Yes, last year the original lower end needed replacement due to a crack in the housing with previous/multiple welds. I found the new lower unit and the shop installed it. They said they checked it out before giving it all back to me. I will not hesitate to bring it back if this isn't something simple and quick enough for me to do.

 

[racerone]

A " new lower unit " or a used one ?----Was the replacement properly checked out or installed as is.-----Myself I would take a replacement unit apart for inspection.---Nothing to it.

 

[F_R]

Check that connector as advised. When you move the shifter lever, the rods and connector should move--with no undue lost motion or slop. If that is ok, take it back. However, if there is lost motion or slop, that is a separate problem. There are several wear points up above, not the least of which is a possible broken clevis under the powerhead.

 

[Fredrunabout]

Okay, between the rain and work I got the two cover plates off and inspected the rods and brass coupler. They are connected just fine and there is no loose motion or slop. I disconnected the cable and when I manually move the lever, the rods move up and down appropriately. I can see and feel them pop into the 3 positions, reverse neutral and forward when I move the lever. Anything else I can do? I just don't want this mechanic to have the boat for several weeks if it is simple and I can fix this myself.

 

[lindy46]

So is it going into forward when you disconnect the cable and manually shift? Is the prop turning when you turn the flywheel?

 

[Fredrunabout]

Yes, I've disconnected the cable and had someone hold the shift lever down in forward postition and it will turn the prop and move forward but if it isn't held firmly it pops out of gear. I've adjusted the cable to try and pull the shifter down more so, but there is no amount of cable adjustment that will do it enough to put it into forward. I've spent a lot of time trying to adjust the cable.

 

[racerone]

No adjusting will help.--------Take this gearbox apart for inspection !!--------Sounds like the classic gear and clutch dogs rounded off.----Not hard to do and you will learn this simple stuff.

 

[F_R]

Shifter lever on motor is adjustable by loosening the two screws in it. But that won't help if the dog and gear are worn out. If it is to work reliably and not just quickly wear out again, EVERYTHING must be in good condition and properly adjusted.

Also, always adjust the remote control to fit the motor, never adjust the motor to fit the remote control.

 

[Fredrunabout]

Thanks for the good tip! I'll try that today.

 

[Fredrunabout]

F_R, I removed the 2 screws from the shifter lever and removed the lever, but there isn't an obvious way to adjust it's position on the shaft. The 2 screws secure the lever to the end of the shaft. It's the shaft that looks as though it would have to be what's adjusted.

 

[HighTrim]

From what you describe, there is something going on inside the gearcase. It will need to be opened up to see why.

 

[Fredrunabout]

Well I think I'll have to take it in. I can't adjust the shift lever on the side of the motor, and when I manually put it into forward it pops out when I hit the throttle.

 

[Fredrunabout]

I now believe that the forward gear is stripped or damaged. I am going to open it up and switch the reverse gear with the forward gear. Anybody do this before?

 

[HighTrim]

Open it up and inspect the lugs on the gears, and especially the clutch dog between them and let us know what you find. Rounding on the edges of the lugs indicates wear.