Bravo 3 Shift Cam Position

[Raptor61]

Hi All,

I just replaced the cone clutch on a 2014 Bravo 3 drive and am having trouble aligning the shift cam before re-installing the drive. I believe the cam needs to be centered so that the shift rod receiver protrudes out a bit to receive the shift cable end when installing the drive. I can't seem to manually "shift" gears so that the cam will rotate into position to install the drive. I have the gears aligned with a "+" lined up with a "-". I've seen some information out there but it is pretty vague when it comes to adjusting the clutch in the gear stack when installing.

Any help will be appreciated!

 

[dubs283]

Once the drive is assembled in order to shift the drive into/out of gear the splined/u joint shaft needs to be rotated clockwise while pulling out on the linkage end. This will allow you to rotate the props during install which will allow the splined shaft to rotate so proper engagement of the coupler splines is achieved

The remote should be in neutral during install and the adjustment of the cables should be correct. Once the jaws of the linkage accept the ball end of the cable the splines of the shafts will be engaged and the drive ought to move forward enough to install the washers and nuts to complete the drive install.

The shift cable ball should shift the drive into neutral after install. Test this by confirming the remote is still in the neutral position and the props spin freely

Once the trim rams are connected and speedometer connection is complete you'll be boating

 

[Raptor61]

Thanks so much for the help. The one piece I found most helpful was to rotate the prop shaft in order to shift into gear to push the linkage out enough to receive the ball end of the cable. I was able to reinstall the drive and the cable pushed the drive back into neutral nicely. Just tested it and it does shift into forward and reverse but with a clunk now. Once in gear, it runs smoothly even under acceleration.

The adjustment seems to be correct since it does engage both forward and reverse and back to neutral, except for the clunk when shifting. Almost like an Alpha drive does without a clutch cone.

I did replace the clutch cone with new style springs and everything went in smoothly. Now for the clunk noise when shifting into gear!

Thanks.

 

[alldodge]

No issue with the clunk, motor turning at 600 RPM and clutch engages gears and starts turning a prop

 

[Raptor61]

I agree that there will be a bit of a gear engagement "bump" at high 600 RPM when shifting but before the clutch cone replacement, there was very smooth shifting much like an automatic transmission. I'm hoping a slight adjustment on the shift cable may help and that the drive does not have to come off. Alpha drives have the iconic clunk when engaging the gears and I have one of those as well.

Any other helpful hints would be appreciated!

Thanks.

 

[dubs283]

If the drive shifted smooth before why did you replace the cone clutch?

Ime some bravos clunk, others do not some only clunk shifting one direction and these are drives that shift properly with full detent/in gear engagement both directions.

 

[Raptor61]

Replaced the cone clutch due to hesitation on shifting into forward due to wear and glazing on one end of the clutch, which I found when I removed it. I lived with it for 18 months or so until I got the part and felt like tearing it apart. It appears that the hesitation is solved now with the new clutch, but I've introduced the "clunk" in both directions and sounds worse than my Alpha going into gear, so there is definitely an issue. Light clunk due to engaging gears would be okay but there is more going on here.

I also would have expected the issue to be more pronounced in forward or reverse if there were a cable out of adjustment but it reacts in the same way in both directions. The throttle, I believe, could easily go into forward or reverse with engine off (not recommended to do that often) but now it is very tight and I don't force it. Won't go into gear at all with no RPMs now and feels like something is binding in the shift cam/linkage area. I did align the gears on installation with a "+" lined up with a "-".

 

[dubs283]

Afraid aside from witnessing in person I can be of no further help

Maybe find a reputable repair place on the water? Ask them for an opinion on the shift. Sometimes perspective makes a big difference

 

[Raptor61]

Thanks, I may discuss with a trusted Merc mechanic if I don't make any progress over the next few days. I've also been reading that some mechanics say that Bravos come from the factory with very smooth shifting, which is tough on the cone clutches, and then develop the shifting "clunk" when repaired for gear or clutch issues. I suspect this can be due to parts wearing and not quite going back in like brand new. I also hear that the detent ball can be too stiff and they cut a coil off the spring behind it to loosen it up a bit.

More troubleshooting to come tomorrow.

 

[dubs283]

I also hear that the detent ball can be too stiff and they cut a coil off the spring behind it to loosen it up a bit.

I've never heard of this type of modification to a bravo shift system. Seems a bit shade tree to me as the ends of the spring are ground flat/perpendicular so as to aid in centering the detent ball assy within the back cover cavity

I have heard of and installed a ramped linkage in place of a high bump linkage to alleviate the force required of the operator to fully engage the detent in the remote. It works with some success but really has nothing to do with a clunk into gear

I think at this point the most plausible explanation is the mating of new and used components, i.e. a new cone clutch engaging with used gear races

 

[04fxdwgi25]

Perhaps, being an older drive, perhaps he is hearing the gears engage when there is added lash between the aged gear train.

Smooth shifting is what the bravo cone was developed for.

With Dubs283 on what I have experienced / seen / heard with the Bravo cone and ramp.