1994 Mercury 40HP, No reverse

R_Woj

Cadet
Joined
Jun 2, 2011
Messages
17
Re: 1994 Mercury 40HP, No reverse

Now that's a great memory.. Haha (trailer incident). Being run over sounds like a bad day!

So it sounds like u had the gear case apart before when u did the shift shaft? If u had fwd when u went in reverse was ur shift cam upside down?
 

R_Woj

Cadet
Joined
Jun 2, 2011
Messages
17
Re: 1994 Mercury 40HP, No reverse

well... solved my problem! shift cam was upside down... had to tear it all apart again... just finished adjusting cables... all good here :)

if you did a 'shift-shaft' job last year and are had problems with forward/reverse being backwards maybe ur looking at the same thing? any chance that shift cam moved or flipped when u had the shift shaft out?

-\Rob
 

R_Woj

Cadet
Joined
Jun 2, 2011
Messages
17
Re: 1994 Mercury 40HP, No reverse

ohh. ps. i removed a peice of shim on the reverse gear!
 

Joel K

Seaman Apprentice
Joined
Feb 20, 2004
Messages
31
Re: 1994 Mercury 40HP, No reverse

I can't say it was a great memory, but it did make for a great lesson later......in that you should ask your Dad or help to get out of the way before you even try to start the thing! Being hit by the prop didn't turn out to be as bad as it could have either. Can't tell the whole story here, but it only hit one leg and I didn't lose it or anything. I could probably teach the dangers of boating if someone was as ignorant of boats as I was way back then. And the Doctor got to teach some interns at the hospital what bone marrow and the underneath side of a kneecap looks like.


No. This is the first time I've been into the gears. A boat shop was in there once, but that was probably 15 years ago. If you search for shift shaft problems you'll find someone describe the problem I had somewhere, but mine was several years ago. I re-installed the LU then from the Clymer manual, and I don't think it mentions anywhere how to ensure everything is lined up right. Had to find that answer later by reading these boards. If you can imagine everything you try to do working in the reverse of what you're expecting, that'll give you some idea of my shift shaft problem. (And I'm still talking boats now, not sex. Although there are probably many similarities).

Really glad you solved your problem though! (With your boat).

I got a good look at the reverse gear I bought, and while the total length between the backside of the ball bearing and front side of the gear is the same, the thrust washer that sits inbetween has about 1/8" or more slop because the thickness of the inside of the gear is less than what I'm replacing. I'm still trying to determine if that will be a problem. I hope to know by Wednesday.

Thank you!
 

R_Woj

Cadet
Joined
Jun 2, 2011
Messages
17
Re: 1994 Mercury 40HP, No reverse

Thanks man... hopefully it goes well for u on Wednesday! Is your reverse gear shimmed?
 

Joel K

Seaman Apprentice
Joined
Feb 20, 2004
Messages
31
Re: 1994 Mercury 40HP, No reverse

No. There are no shims. I did get it put back together today and was only able to test it with the muffs. It's hitting reverse on dry land, now if if it'll just do it Wednesday when I drag it back out to the lake. I did adjust the shift cable to give it about 1/4 inch more travel towards reverse. Wish me luck.
 

Joel K

Seaman Apprentice
Joined
Feb 20, 2004
Messages
31
Re: 1994 Mercury 40HP, No reverse

I have reverse again. At least for about 20 tests on the lake.
My hypothesis. I replaced the reverse gear and clutch because of the minor rounding but really doubt they were the problem. I tried it after the new gears and it would go in, but there was also a minor difference in the gap of the thrust washer. I moved the shift cable about a 1/4 inch in the wrong direction the first time and lost reverse when I did that. I moved the cable adjust back 1/4 inch in the correct direction to lengthen the cable from where I'd originally started and it seemed to lock in solid. So I think my cable had stretched or otherwise moved out of adjustment over time which caused it to not have enough stroke to positively lock up reverse.

And I probably spent a lot of money and time waiting on parts for nothing. But that pretty much sums up the story of my life.

Thank you both for your help! And good luck to you in the future.
And always remember to keep your boat as far away from water as possible. Even getting a boat near water is just asking for trouble.
 
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