Came out of gear, won't go back in gear, no noise

[alskntwnsfn]

Here's what I know about my boat, which unfortunately isn't much:

1. The outdrive is a OMC, electric shift. The outdrive model number is #981227, 225 HP. The lower unit is probably 2-3 years old, so says the gentlemen I bought if from last summer. Even though the unit is 'newer' I believe it was manufactured back in the late 70's or early 80's and has been rebuilt. The SELOC manual that came with the outdrive covers units from 1964-1986, and the unit pictured on the cover looks exactly like mine.

2. I think my engine is a Chevy 350. My identification says the engine model number 990211A11. It's got about 820 hours on it, and runs well, but has had a number of electrical connector problems.

About my problem:

Took it out the for the first time this year, it shifted into forward easily in the harbor. We trolled out of the harbor and I started pushing up the RPMs. I got to about 2500rpm and it came out gear, going into neutral. No grinding or anything from the outdrive. It just came out of gear, and wouldn't go back in. Again, no grinding or noises, when I flipped the gear switch into forward/reverse, there's just nothing. We let it idle for about 15 minutes while I warmed up the kicker. Then we noticed the engine was overheating.

Now a few days later, we've replaced the starter, because it had a broken bushing. It starts much better, and still idles fine. It didn't have any overheating problems while we let it idle for about 15 minutes in my driveway (while we had the garden hose running water through the outdrive). We check the ohms going into/out-of the outdrive, and they all read a normal 12, depending on whether its in fwd or reverse. Finally, the prop pin is fine. That hasn't been sheared. We've been hesitant to start taking the outdrive apart, as we don't know much about it compared to engine-related matter.

One more thing:
- The outdrive gear that links up with the engine does not spin when we spin the propeller. The prop spins easily, that outdrive gear however can not be turned by hand.

Does anybody have any ideas about what is going on here? Is the problem a bad switch up by my ignition (the only "easy" thing I haven't checked). Is it a problem with the electrical cables, or the magnets, or something else? I guess I'm just looking for some guidance as to what could be the issue with it not shifting into gear.

 

[bruceb58]

Re: Came out of gear, won't go back in gear, no noise

Since your engine started overheating, that means the stern drive is not connected to the engine anymore. Check to see if the ball gears are rotating when the engine is idling. If they are, your problem is in the drive somewhere.

Not sure where you have the water connected. If you have the fitting that is up at the trunions, you are bypassing the water pump.

 

[fendersfender]

Re: Came out of gear, won't go back in gear, no noise

It surely broke the water pump shaft...this is a common problem with these...remove drive from boat, separate the upper and lower gearcases, remove water pump assembly and check condition of that water pump shaft...i will almost bet you that is either broken or the splines are ate away....use you manual..its not that hard and.....you can find parts at....http://www.sterndrive.info/800_series_water_pump_parts.html

 

[alskntwnsfn]

Re: Came out of gear, won't go back in gear, no noise

Thanks for the help guys. You're probably right, because I performed another check.

I had someone put it in gear, and turned the prop. I could hear the magnets magnetize, and it was obviously in gear in the lower unit. I was able to turn the prop, and could hear/feel the lower driveshaft turning when I turned the prop. However, the ball gear at the top of the drive doesn't turn.

So it looks like my problem is in the upper unit, in the shaft that attaches to the ball gear. My garden hose attaches to the top of the unit, close to the boot.

Thank you guys so much for the prompt help. You're angels (with dirty fingernails )!

 

[chiefalen]

Re: Came out of gear, won't go back in gear, no noise

when its running is the ball gear turning coming out of the intermideate housing?if not its the coupler.if yes water pump shaft stripped out.

 

[alskntwnsfn]

Re: Came out of gear, won't go back in gear, no noise

Update!!

Pulled off the outdrive, and have found a place that will repair it. However, the ball gear on the intermediate housing will need to be replaced as well. It is very worn down. I pulled out the bolts, but cannot get the ball gear shaft to come out. The part of the shaft I can see, in the middle of the ball gear, is quite rusted.

Also, I can't believe I did this, but in my frustration to get the mounting bolts off the plate that holds the ball gear shaft in place, I rotated the ball gear (which should rotate the crankshaft inside the motor. I'm not positive that I was able to return the crankshaft to its original position.

So, basically, I can't get the ball gear shaft out. The manual says something about possibly having to pull the engine and the intermediate housing. Will I have a problem with my pistons firing correctly because I turned the crankshaft? And fixing the upper outdrive unit will run at least $700. Probably closer to $1000 with the ball gear replacement and shipping. Also, there isn't really anybody in town who works on those, so if anything else went after I replaced it... I'd have to send it out again.

I've attached a picture of the boat. I bought it a 1.5 year ago for $6700. I've had it out probably a dozen times, but I've spent at least 5 times as much time fixing it.

If I have to pull the motor, or even the intermediate housing. My plan is to just put an outboard on. Anybody here ever bought motors off craigslist or ebay? Outboards can have problems too, but at least there is someone here to work on them and they are more contained.

Outfitting it with a 225 hp motor from the mid-late 90's would probably run me somewhere around $4-6K depending on the outboard I get. But as it is now, my boat is practically worthless without power. I'd also really like to have the extra deck space. Right now my inboard housing takes up most of the deck in back, making fishing kinda tricky.

Comments/suggestions??

Any suggestions?

 

[chiefalen]

Re: Came out of gear, won't go back in gear, no noise

You say you have the outdrive off. Go in the boat and take the middle plug off the distributor. Have someone watch that ball gear that comes out of the back of the boat.

Crank the the engine for a second. If the ball gear moves, its the shaft in the outdrive that is stripped. If it doesn't turn, its the coupler and the motor

has to come out to fix.

Now to pull that ball gear shaft, you have off the gimble bearing retainer off

already. Nothing else holds it in, good ole american muscle it out. New

gimble bearing and and ball gears, you have to do both, and your good to go.

If you have to replace the shaft do the water pump also.

good luck

 

[WizeOne]

Re: Came out of gear, won't go back in gear, no noise

Do as chiefalen says. Electric shift couplers/drive shafts were fairly finely splined. They did strip out. Later couplers and shafts had courser splines which were not prone to wearing out and stripping.

The good news is that the later parts are interchangable with what you have. You might have to watch ebay to get them at an affordable price.

Careful though, with no load on the intermediate shaft, the ball gear might still turn even though the coupler is stripped.

I don't remember whether you said you had reverse or not? Without the engine running and the shifter engaged, the forward or reverse shift cones will not be engaged. That means you can spin the prop till you are blue in the face and the outdrive ball gear will not spin. (assuming drive is off)

 

[sea wolf]

Re: Came out of gear, won't go back in gear, no noise

Forget about putting an ob on it. If I were you, I would do the repairs then get rid of it. You will spend more $$$ & time working on it than it's worth. Too bad u didn't check here before sinking $6700 into that boat. If you did you would have gotten a good reaming for even thinking about it.

 

[alskntwnsfn]

Re: Came out of gear, won't go back in gear, no noise

Update:

The water pump shaft on the upper case moves. When the shaft is fully extended, the gears turn normally. However, when the shaft is pushed in, the ball gear doesn't turn the water pump shaft that sticks out the bottom of the upper gear case.

So I'm trying to remove the water pump shaft and water pump housing. I've got the impeller housing free from the housing, but the shaft still won't come out.

My outdrive's serial number ends in 54... so it's a '54?

Has anyone had a problem getting the impeller, housing, and water pump shaft out? The manual makes it sound like once the housing is free, the shaft pulls right out. Is there an o-ring, or some kind of key, or something else inside there?

I'm pretty sure that once I figure out what is causing that shaft to move back and forth, I'll have it fixed. I'm glad I didn't get a whole new gear case, which is what i've been looking for. I'd take it into a shop, but unfortunately nobody in town will work on these old electric shift outdrives.

Also... thanks for the tip about getting the ball gear off. I did apply a little more muscle and leverage, and presto.

 

[chiefalen]

Re: Came out of gear, won't go back in gear, no noise

You ever get a manual?

You say you removed the water pump and shaft from the upper?

The shaft and water pump housing all come out as one unit. There is actually 2 shafts that connect with a key. And a gear also. It's all one unit.

Wizeone i have 2 drive shafts with ball gears on them that came out of electric shift stingers.

They both have 24-25 teeth mine has 20 teeth. They do not interchange.

 

[alskntwnsfn]

Re: Came out of gear, won't go back in gear, no noise

You ever get a manual?

You say you removed the water pump and shaft from the upper?

The shaft and water pump housing all come out as one unit. There is actually 2 shafts that connect with a key. And a gear also. It's all one unit.

Wizeone i have 2 drive shafts with ball gears on them that came out of electric shift stingers.

They both have 24-25 teeth mine has 20 teeth. They do not interchange.

Well, I'm trying to get the shaft out but its stuck. The manual says the shaft and water pump housing come out as one unit.

Here's some pictures...

 

[alskntwnsfn]

Re: Came out of gear, won't go back in gear, no noise

Here's the shaft in the extended position. In this position the gears function normally. The ball gear spins the shaft at the bottom of the upper case. But in the next picture, if you look close, you can see the shaft is push in about a half inch, in this position, somehow the gears become disengaged.

 

[alskntwnsfn]

Re: Came out of gear, won't go back in gear, no noise

Here's the shaft in the contracted position... it shouldn't move, right?