Alpha Gen 2 Shift Cable Removal

[Cruize]

The threaded brass end of the shift cable sheath that attaches to the bell housing does not want to come out. The flats on the brass fitting started to round while using the removal tool.

How do I get the brass part off? Do I drill it out from the transom side? Do I hack it apart from the outdrive side and try an easy-out?

How important is it to change the sheath? Can I just install a new cable in the old sheath and replace everything else? I have no idea the age of the existing shift cable, but the cable "looks" OK. I only used my boat a few times a year for the past 10 years and probably only put 100 hours on in that time. At least three years, it never made it out the back yard.

If I mess up the sheath and can't get the fitting, I'll need a new bell housing. It may not be ideal, but reusing the sheath sounds like a safer option.

Opinions?

Thanks!

 

[MarcelSydney]

If you can still grab it, you could try heating the aluminium around it with a blow torch, see if it loosens.
Easy outs might work, but the brass was so soft when I did it, it just ate the fitting.
I ended up having to drill it out and cutting a new thread. If you end up doing that, careful not to drill too big!

 

[Bt Doctur]

try heat and hammering a metric socket on it .If that fails, drill and retap for the straight tap.NOT A 1/4 INCH PIPE THREAD

 

[dubs283]

Like others say try heating the area around the insert and unthreading it with an appropriate socket

If you can't remove it conventionally you may have to drill it out and run a tap through the hole

You'll need a 1/4-18 NPS tap that requires a 7/16" pilot hole

It'd be best to start with a smaller drill than 7/16" and work through larger diameters to achieve proper 7/16" hole for the tap

 

[nola mike]

I was surprised how well these worked last time I ran into this. And yes, the sheath wears on the inside and needs replacing



TOPEC 5-Piece Spiral Type Deep Extractor Set, Spark Plug Easy-out Set, for Removing Deeply trapped and Broken Bolts, Studs, Fittings, Threaded Pipes and Pins https://a.co/d/bW7b0pX

 

[stresspoint]

been there played that tune with a busted one , snapped when i tried to undo it "" first experience changing a cable as i did not have the correct tool".

cut the cable from behind and drill out the remainder ,the drill bit centers easy down where the cable inner runs ,so no issue there.

use a drill bit slightly smaller than needed and chip out the threads as you will find corrosion in the threads if sealer was not used previously.

NOTE, just be careful not to nip the drive oil hose with the cut off wheel as i did .