Lower unit shift shaft boot problem

[dancamp007]

Hi. When I drained the gearcase oil I noticed the blue salt-away solution had accumulated inside and the oil itself was very milky. On retrospect, I realize I was probably responsible for the blue fluid as I plugged up the little drain holes while I was filled the thermostat hole with salt-away to clean out the water jackets and this proabably caused the problem. But, being the jerk I am, I didn't realize that and so when I did a air pressure test I think I may have blown a hole in the shift shaft boot as I hear air coming out of that area, so I wanted to remove the shift shaft boot and unscrewed the phillups screw, but it wouldn't pop out. So I pulled on the boot with no success. Then I pulled on the shaft itself and it seems to have pulled out about a half inch, but the that was all and the boot still wouldn't come out. Now I just want to get the shaft back in the original location and put it all back together, but the shaft doesn't seem to want to go back down that half inch. I've tried rocking the gears a little back and forth without success. The big virticl drive shaft doesn't seem to turn at all with little force, though the propeller shaft will turn a little. Please tell me what I have to do to change the shift shaft boot and get that shift shaft back in it's original position. My Clymer Yamaha ship manual doesn't tell me how to get the shift shaft back in place.<br />Thank you for any help on this problem.

 

[dancamp007]

Re: Lower unit shift shaft boot problem

Forgot to mention that this is Yamaha T9.9 model if this helps.

 

[rodbolt]

Re: Lower unit shift shaft boot problem

I will have to double check my manual but I think if you have disengaged the shift cam from the pin you will have to remove the propshaft to reassemble it. but let me try to double check tomorrow.<br /> what is the full model #?

 

[dancamp007]

Re: Lower unit shift shaft boot problem

T9.9MXHR is the whole model number. Thank you rodbolt for your help. much appreciated.

 

[rodbolt]

Re: Lower unit shift shaft boot problem

dont have my service manual for that here but ill try to remember to look at it tommorrow.but memory says if you pull the shaft up high enough the shift cam will allow the follower pin to pop out requiring propshaft removal to reassemble.

 

[dancamp007]

Re: Lower unit shift shaft boot problem

Yikes, I just hope not. Is there a way to test it while the whole gearcase is still together?<br />thanks again. I will wait for your update tomarrow too.

 

[dancamp007]

Re: Lower unit shift shaft boot problem

also, I tried plugging up the drain holes and poured water in from above and the whole cup of water seeped into the gearcase (past the boot) within 7 seconds. So I probably have to replace the boot anyway. Can I get that out without pulling the shift shaft out, or should I just go ahead now and pull the whole shift shaft out, replace the boot and wait for your next update on wheather or not I have to break open the whole case? thanks again

 

[dancamp007]

Re: Lower unit shift shaft boot problem

OK, I see the shift shaft is still engaged and I am able to put it in forward, neutral, and reverse. Wheew. Now my only problem is getting out that boot to replace which is being stubborn. I can get a hooked wire under the screw hole of the retainer screw, but it only bends the retainer and doesn't want to pop up and out like I think it should. I'm afraid I'll brake it if I pull too hard. Is there a trick to getting these boots off or should I just go ahead and keep yanking on it? <br />thanks again

 

[dancamp007]

Re: Lower unit shift shaft boot problem

Update: I have now figured out that the leak is occuring below the retainer screw. When I pour water in from the top of the gearcase and apply air pressure to the gearcase oil input hole, I see air bubbles coming up from the water drain hole next to the retainer screw that goes down into the drain cavity. So now I'm wondering if I have a crack or hole down there in that drain cavity that opens up into the gearcase. Could this be possible?

 

[dancamp007]

Re: Lower unit shift shaft boot problem

How hard do you have to pull on this shift shaft plastic retainer to get it to pop out anyway? I'm pulling so hard on the little screw hole with a hooked wire but it won't budge. At this rate it's either going to tear apart or pull out. And the shift shaft doesn't want to come out either, or I'd use it to pop the retainer out. The shaft won't pull out no matter how hard I pull with my bare hands. I guess I need to pull with vicegrips and maybe even wedge them to get the shaft out? This year 1993 doesn't seem to have any pin stuck into the shaft holding it in there. It's just a tapered end that fits in the gears according to the drawing. I guess I'm just hoping some hot mechanic familiar with this particular problem will advise me before I distroy this poor gear case. <br />Good luck huh??? I did find a couple used gear cases for sale, but I don't like the prices or .

 

[dancamp007]

Re: Lower unit shift shaft boot problem

I tested it for leaks by screwing in the lower case screws and soaking it in water up to the peep holes for one minute, then checking the gear fluid. I get a lot of water accumulation in gear case when water level goes over the highest peep hole, and little water reaches only the lower hole. so my I have a leak. The air test blows air bubble out the drain hole next to the retainer screw. think I'm screwed. . .

 

[rodbolt]

Re: Lower unit shift shaft boot problem

do you have a servce manual?

 

[rodbolt]

Re: Lower unit shift shaft boot problem

go to the yamaha parts website<br /> http://www.yamaha-motor.com/outboard/parts/home.aspx <br /> and give me the reference number of what your trying to pull out. you may also have a driveshaft seal leaking. if its the bracket#51 it may be a bit corroded in place but once the retainer screw is removed it will lift out.

 

[dancamp007]

Re: Lower unit shift shaft boot problem

Problem solved. The shift gasket was dirty and tilted and just needed to be removed, cleaned and reinstalled. Took a mighty grip with vicegrips to pull the shift shaft out first. Thanks for the help.

 

[dancamp007]

Re: Lower unit shift shaft boot problem

That was parts 56-59 shift shaft 1993 yamaha T9.9MXHR . http://www.yamaha-motor.com/outboard/parts/home.aspx <br />thanks again