merc alpha 1 won't go into gear

[hundel]

Just got done removing outdrive on merc 4cyl 224ci w/alpha 1 gen 1. Successfully replaced gimball and all bellows.<br /><br />No sooner did I get shift cable adjstd and back in water, o/d started whirring instead of going in to fwd/rev. <br /><br />Pulled boat from water and shifter appears to be moving the shift lever properly, but I am able to turn the prop by hand when in gear. In one direction, with clicking, in other direction, with rubber-on-rubber squeaking noises. Is this a sign of lower unit damage or should I take the o/d back off and take inventory?

 

[tema]

Re: merc alpha 1 won't go into gear

Sorry hundel, I would help if I could, because then I probably would be able to solve my own problem too, which is similar. I have a 1967 Merc 50 hp, which suddenly decided it wouldn't go into gear... the shift lever seems ok, the shift rod turns like it should (I believe), but the gear will not engage. In forward or reverse, there is a distinct sound of something rotating inside the lower unit, not so in neutral. I tried to have a look inside the lower unit to see if something was loose in there, but the unit is stuck on the gearshift rod. The Seloc manual says it has to be in forward when removing the L.U., so probably the reason it's stuck is connected to the original problem. So my question is: Does anybody have a clue as to what I can do to remove the lower unit, and what might be the gearshift problem in the first place? I think my problem is (at least partly) the same as Hundel's problem, so now we are at least two people hoping for some friendly advice.

 

[hundel]

Re: merc alpha 1 won't go into gear

That's right. The sound is different from in neutral. I'm considering pulling the lower unit off. Can you turn the prop when the lower unit shift lever is full forward?

 

[hondon]

Re: merc alpha 1 won't go into gear

Yes you can turn the prop clockwise in forward gear and counterwise in reverse,and you will hear the gears ratcheting if you do it the other way.Is it possible you have a spun engine coupler?

 

[tema]

Re: merc alpha 1 won't go into gear

Well, in my case I can turn the prop both ways with exactly the same sound and feedback, and it makes no difference if the gear is forward or reverse. The only difference is neutral, where the prop moves freely. And Hundel, I'm not sure what you mean by shift lever full forward, as far as I can see, it's either forward or not forward. Anyway, I can always turn the prop together with some stuff inside the LU, but exactly what that might be I'm unable to investigate, as the LU is stuck on the gearshift rod. I too would like to pull off the LU, but in my case it's how much force should I use, and what would I break. I would prefer having it off a bit more smoothly.

 

[hundel]

Re: merc alpha 1 won't go into gear

here is the diagnostic tip I learned, and it may help you guys too: rotate prop in gear, watch u-joint yolk/main shaft. <br /><br />If shaft turns, but engine does not it is definitely on the engine side of things, which means...the coupler. I believe this requires engine removal on my model.<br /><br />If the u-joint yolk/shaft does not turn, the problem is in the lower unit gears.<br /><br />My coupler appears to be the problem!

 

[SS MAYFLOAT]

Re: merc alpha 1 won't go into gear

I'm not saying that the following is your problem, but something like your problem had happened to me. Your problem could be between your gimbal housing and your outdrive. There is a rod at the end of the shift cable that moves in and out when you move your shifter. That rod is about half inch square and about 3 inches long. It has a couple of fingers that stick out to accept the shifter bellcrank that ties the upper and lower unit together. The should be a small roller bearing at the end of the bellcrank. This bearing has to be between those fingers on that rod. If the rod gets turned when you put your outdrive on the gimbal, Your shifter will not work, or if it does, it won't work long. The clicking you hear is basically like a clutch, when your crusing and then suddenly pull your throttle to an idle, the motion of the boat moving forward will cause the prop to spin free instead of acting like a brake, it actually allows you to coast somewhat. Personally I had to R&R my outdrive 4 to 5 times the first time to get everthing done right!<br /><br /><br />"Ignorance is the root of high dollar repairs"

 

[hundel]

Re: merc alpha 1 won't go into gear

And me having just put the outdrive on that day makes that a likely possibility for me. Would the main shaft still turn when I rotated the prop in this case?

 

[scarchest]

Re: merc alpha 1 won't go into gear

I am no expert,but it sounds as if you reinstalled lower unit in neutral, on most <br />Mercurys, they need to be installed while in foward gear

 

[hundel]

Re: merc alpha 1 won't go into gear

I think we can rule that out since the shift lever at the LOWER unit is moving properly. If the cable wasn't turning the shift rod, I don't think we'd see the lever rotate on the lower unit.

 

[tema]

Re: merc alpha 1 won't go into gear

I was inclined to accept Hundel's conclusion, as that was my first thought when the problem arose. However, ss Mayfloat's suggestion is certainly interesting, although I don't know if it's appropriate to my 67 Merc 500, because I can't remember the rod to the bellcrank being as much as a half inch square, or a roller bearing at the bellcrank, but for sure I'll check on first occation. Alas, that may take a week or two. I'm still puzzled though, as to why the lower unit is stuck...

 

[tema]

Re: merc alpha 1 won't go into gear

Ok Hundel, you may be right, if the shift rod turns at the lower unit, the shift cable and all that is probably ok. On the other hand, it might turn in an inappropriate way, if you know what I mean... it may not turn as much as it should, or at an incorrect angle, or something like that. So I would still consider all options...

 

[hundel]

Re: merc alpha 1 won't go into gear

Maybe we can rule that out by gently verifying it is fully rotated using a screwdriver. <br /><br />I believe the manual says neutral (to the lower unit) means only that the prop shaft is freed via the dog clutch - so everything else is turning whether you're in gear or not. If you can turn the u-joint yolk/main shaft using the prop, I think you must be in gear, and if the engine is not preventing that rotation, then I don't think it's coupled properly.<br /><br />What happens to yours when you turn the shift lever full forward, grab the prop, and turn? Can someone else verify whether the shaft is rotating in the coupler?

 

[SS MAYFLOAT]

Re: merc alpha 1 won't go into gear

When you first removed your outdrive, did you have in forward gear? And as far as tema's problem, the outboard and I/O are different in how the cable connects to the shifting componets. If you did not have your outdrive in forward gear, and had to wrestle it off with brute force like I did once, It can bend the brass shoe/shaft that comes up from the lower unit. If this gets bent, it can prevent proper shifting to the lower unit and change your adjustments. Try using a screw dirver to shift it into forward. It is tricky but you can look up underneath to look inside where the shoe meets up with the bellcrank shaft. The shoe should be point straight at the back of the boat to be in forward gear, and for reverse it should point toward the starboard side. If that shoe is not pointed straight forward when it is shifted into forward, something is bent or just out of adjustment. I sort of refuse to believe that something is wrong with your lower unit if it was okay before you started changing your gimbal bearing.<br /><br />You must remember only the shifting is completely done in the lower drive unit, so when you are in neutral, the input shaft (where the u-joints are) should not turn. If it does, make sure that The brass shaft with the shoe on it is pointing at about 1:30 with 12 oclock being straight ahead and reverse being about 3 oclock. Hopefully this helps you.<br />One time I had problems with inside the bildge area where the primay cable from the shifter ties into the outdrive cable. A piece of housing broke and didn't allow me to get the proper stroke to fully enguage the outdrive.

 

[tema]

Re: merc alpha 1 won't go into gear

Yes Mayfloat, that sounds very sensible, and the gearshaft being out of adjustment is consistent with all symptoms, except the fact that when the gear is set in neutral with the remote control, it really is neutral, so when the prop is turned nothing else inside the LU moves. That should indicate that the gearshaft is correctly adjusted. And when put in forward, the bellcrank moves as far as possible, and stops against an item in the motor housing. I'm mainly leaning towards the conclusion that there is something wrong with the connection between the engine and the driveshaft, or the gear and the driveshaft. It's difficult to see if the driveshaft moves when the prop is turned in gear, because it's protected by some plastic housing between the lower unit and the upper part, but I suspect, as Hundel did, that it's the connection between the engine and the driveshaft. On the other hand, what you are saying could explain why the lower unit is stuck. <br />Oh well, if life was easy I suppose it would be less interesting too... although I'm not quite sure about that either...

 

[clanton]

Re: merc alpha 1 won't go into gear

Did you change shift cable, and cut to the correct length. Shift cable must be in farward gear when installing gearcase or drive.When you turn prop by hand in farward gear it will only lock the clutch dog by turning counter clockwise.

 

[tema]

Re: merc alpha 1 won't go into gear

I don't think mine or Hundel's problem is related to the shift cable or the gearshaft. Either it's the driveshaft connection, or something inside the gearcase. Clutch dog, cogwheels... something is out of position.

 

[hundel]

Re: merc alpha 1 won't go into gear

I removed the o/d in fwd and reinstalled in fwd (according to book). I adjusted cable according to book. I verified that neutral on the hand lever allows prop to spin without turning u-yolk/mainshaft. I verified that fwd or rev on hand causes shaft to turn when prop is turned. Guys, again, if it is the cable or a bent shifter, and the lower unit is not really in gear, why is the yolk turning?<br /><br />Tema - on my model, I can look right down at the u yolk from inside the boat, and it is definitely turning with the prop when in gear. Are you unable to see it? I'm really curious if your problem is the same. Does it kind of squeak when you turn the prop in gear, or is it making grinding noises, or something else?

 

[clanton]

Re: merc alpha 1 won't go into gear

Remove outdrive, use alignment tool with splines or old drive shaft, insert into coupler splines, turn with pipe wrench.

 

[tema]

Re: merc alpha 1 won't go into gear

Hundel - we may well have the same problem, but the engines are different. I can't see the mainshaft or the driveshaft (I suppose that's two names for the same thing), because it extends from right under the powerhead, inside the cover. I can't even see the shaft when the lower unit is loosened about half an inch, which is all I can manage because it hangs on the gearshaft, because of the plastic protection inside. But I can easily se the gearshaft, and it appears to function properly. But I'm afraid I will be unable to investigate further until next weekend.