2003 60 HP Stuck in gear

[chainsaw8]

The shifter was working fine until I removed the lower unit to replace the impeller. When I reinstalled it, the lower unit is stuck in reverse. The boat shifter works freely, but I can't get it in neutral or forward. With the lower unit off, the splined shifter shaft on the lower unit can be turned by hand, but don't change prop direction.

Need some advice since it's almost fishing time!

 

[carholme]

Re: 2003 60 HP Stuck in gear

Chainsaw;

Drop the LU again and make sure that the boat controls are in F or R and that the LU is in the same gear. If you provide the s/n, we can give you a link to the service manual and the procedure.

Gerry

 

[chainsaw8]

Re: 2003 60 HP Stuck in gear

The S/N is OT613731. With the lower unit removed, you can turn the shift rod, probably 1/4 turn in each direction, but the prop stays in reverse.

Any advice is appreciated!

Chainsaw

 

[carholme]

Re: 2003 60 HP Stuck in gear

Chainsaw;

Here is a service manual which will work for your engine s/n:

http://1manual.com/Mercury manuals/Service Manual PDFs/TwoStroke/852572r1/cover.pdf

Scroll down to Lower Unit and select B, 55/60 and go down to page 6B 33 which will show you the actions of the prop when F/N/R is selected. Page 6B 19 (Gear Housing Reassembly) shows the cam and shift shaft. Page 6B 9, item 41 is the cam follower which contacts the detents of the shift cam

Here is a Parts Listing for your engine:

http://www.crowleymarine.com/mercury-outboard/3371.cfm

In the Parts Listing, select Gear Housing 1.64:1 and note item 18 which is the shift shaft which you are turning by hand. See item 36, the shift cam and this is attached to the splines on the lower end of the shift shaft. When the shift shaft is turned by gear selection, it moves the cam which does the gear change.


After reading all of this, you should have an idea of how this works. Now get a socket that will fit the splines of the shift shaft or pliers with a rag around the splines and rotate the shift shaft ccw to take up the play and then move it just a bit more until you feel it lock into a detent. Now by moving the prop according to Page 6B 33, you should know what gear you are in. Then set the boat controls to match that gear and reinstall the LU.

Let me know if this makes sense and if you need to talk, PM me and I will send you my phone number.

Good luck

Gerry`

 

[chainsaw8]

Re: 2003 60 HP Stuck in gear

Gerry,

I see said the blind man............ Problem solved! It worked great just as you described! Apparently, I wasn't putting enough pressure on shift spline. Thanks a bunch for your assistance. I'll dedicate my first fishing trip this spring to you good buddy.

 

[carholme]

Re: 2003 60 HP Stuck in gear

Really glad that it worked out for you and all the best in the coming season.

Gerry