I could use some help

[WyoHntnDude]

I have a 2005 mercury 90 elpto and had the shifter shaft (#36 and the schematics) pulled out on me. The lower unit was in forward gear. How do I get it back in and lined up with the pinion gear? Thanks

 

[racerone]

Re: I could use some help

It does not really line up with the pinion gear at all.-----Post picture of the bottom of the shift rod.----------This engages a pin that moves the clutch dog between the forward and reverse gears,---The pinion gear is always engaged with forward and reverse.

 

[carholme]

Re: I could use some help

Shift shaft, item 36 is held in the lower unit by the E ring, item 37. It is not uncommon for them to have been previously left out or popped out if someone pulled upwards too hard on the shift shaft.

When properly installed the shaft lower splines fit into cam, item 17. Here is a picture of it so you can see what I mean:

http://imageshack.com/a/img828/3793/glm11185.jpg

Depending on what gear it was in before the shaft was pulled out, you may be able to get the shaft splines re-inserted into the cam but it is tricky. Probably the easiest at this point and to recover the E ring, is to remove the bearing carrier assy which will give you access to the cam. You will need the service manual for this, P/N 90-830234 and if you do not have it, see my message to you in Notifications at the top of this page.

Do you have the s/n of your engine?

Gerry

 

[WyoHntnDude]

Re: I could use some help

I understand now that the shifter shaft doesn't connect with the pinion gears. It was forward gear, turned clockwise but stopped counter clockwise. I've tried every way I can think of to get the shaft in without taking the prop and everything out. According to the manual special tools are needed and I don't have them. Serial # 1B171079. Thanks

 

[carholme]

Re: I could use some help

Don't let the special tools fool you. All you need to do is remove the bearing carrier assembly as seen under Section 6A, page 11, paras 1 and 2. Once you have the two bolts removed, you should be able to rotate the carrier a bit and pull the carrier out. This will allow you to get in there and re-connect the shift cam to the shift shaft. You will see the correct shift cam orientation under 6A, page 18, figure 51117.

Your s/n comes up as:

MERCURY - ( 90 H.P. (2005 ))
Serial No: 1B171079 Model No: 1090412DD

Parts List for model 1090412DD:

75/90 HP 65 JET (3 CYLINDER) - Mercury, Mercruiser, Force, etc. Parts Lookup

Gerry

 

[WyoHntnDude]

Re: I could use some help

Here is the pic of the bottom of the shift rod that goes into the cam.

Thanks carholme, I'll give it a go but probably won't get to it til next weekend.