mercury shift shaft removed by accident

[squejyluigi]

removed the shift shaft on merc 135 v6 1990 model by accident when replacing waterpump don't laugh
it won't select anygears now, HELP!
do i have to rebuild the gearbox?
luigi
shift jst spins now

 

[Bob_VT]

Re: mercury shift shaft removed by accident

Welcome to iboats.

Have you removed the lower unit to check this or are you trying it with the shift control at the helm?

You have to shift it with the lower unit off the motor with a pliers and re-assemble the lower unit while it is in gear ....... then check your shifter.

It is a common problem for many not used to doing the impellar on the Merc's

 

[CharlieB]

Re: mercury shift shaft removed by accident

I think he is describing that he 'lifted' the shift shaft up from the lower and 'unplugged' it from the shift cam!

Now he has moved the LU, the cam is out of place and he cannot get the shift shaft to fit into the cam.

He is going to need the service manual to take off the shift shaft cover, get the cam oriented correct, insert the shaft and replace the cover.

 

[squejyluigi]

Re: mercury shift shaft removed by accident

yes tht is correct, i took the lower leg off and pulled out the shift shaft,
i then put in back in and tightened the bolt.

 

[squejyluigi]

Re: mercury shift shaft removed by accident

thanks for that ,
Any ideas in what is involved in reseting the cam? Like i said i pulled out the shaft from the lower unit. wen i put it back in also i have noticed the there is lateral aswell in the shaft as it goes up and down, is that normal?

 

[Faztbullet]

Re: mercury shift shaft removed by accident

You need a service manual to repair as he shaft should have not came out, its held in place with "E" clip. You will need several special tools to remove carrier nut and shift bushing bushing to attemp repair as you need to find clip and the lower unit will need to be disassembled to repair anyway. It may be cheaper to take to a service shop and have it done.

 

[CharlieB]

Re: mercury shift shaft removed by accident

See parts page

http://www.mercruiserparts.com/Show...r=556&bnbr=240&bdesc=GEAR+HOUSING(DRIVESHAFT)

You will need to remove the bushing, item 42, to see down into the case. You may have to drain the LU. Use a magnet or parts 'fingers' (pick-r-upper thingy) to get the cam out.

Check the service manual to be SURE which side is 'up', tap the shift shaft back into place in the cam, reinsert in the case.

Change the seal in the bushing and the o-ring below the bushing, reinstall the bushing.

Turn the shift shaft while turning the vertical shaft to ensure correct shifting.

Reinstall LU and add oil.

Double check shifting with control box.

 

[squejyluigi]

Re: mercury shift shaft removed by accident

Thank you for the help guys

CharlieB does this mean i do not have to rebuild the full box?

 

[CharlieB]

Re: mercury shift shaft removed by accident

If all was well before this incident, shifted O.K., then no, you only need to reassemble the shift mechanism correctly.

You really should replace the seal and O-ring, as you would any other type of gasket that is disturbed during any dis-assembly.

 

[CharlieB]

Re: mercury shift shaft removed by accident

Re-read Faztbullet's post, you NEED to find that E-clip, item #39 in the parts view. Order a new one, locate, remove and throw away the old one, do NOT reuse it.

 

[squejyluigi]

Re: mercury shift shaft removed by accident

wjen i removed the shaft, i unscrewed the bush nut and took the hole thing out, the e-clip is intacked, when i replace the bush nut the rod just spins, is it meant to do that?

 

[carholme]

Re: mercury shift shaft removed by accident

No, it is not supposed to do that. The shaft is spinning because the splined end of the shaft is not engaging the shift cam.




If you can provide the s/n of your engine, I may be able to give you the procedure to do this right.

carholme

 

[emckelvy]

Re: mercury shift shaft removed by accident

Check this older posting, there may be info in it that'll help you get that shift shaft reinstalled without complete disassembly of the lower unit:

http://forums.iboats.com/showthread.php?t=264376

HTH...........ed

 

[squejyluigi]

Re: mercury shift shaft removed by accident

carholme
the serial number is OD253726
that would be much appreciated
thank you

emckelvy
still trying to suceed with that post
thnaks

 

[carholme]

Re: mercury shift shaft removed by accident

Here is the maintenance procedures for the s/n which you have listed.

http://1manual.com/Mercury manuals/Service Manual PDFs/TwoStroke/824052r3/cover.pdf

Scroll down to Section 6 "Lower Unit" and select the type of lower unit you have.

If you haven't been able to locate a position to fit the shaft as per the emckelvy post, I suggest you tear it down with these instructions to get your shaft correctly oriented in the cam.

Let us know if we can help further

Regards

carholme

 

[squejyluigi]

Re: mercury shift shaft removed by accident

anyone got any ideas on how to remove the big retaining ring behind the prop to remove the gear shaft? i do not have the tool.

 

[carholme]

Re: mercury shift shaft removed by accident

squejyluigi;

Do you have a Merc dealer close to you? Where are you located? The best thing would be to borrow or rent the tool. I have my own homemade socket setup, similiar to the one shown in the maintenance procedure. The cover nut is only $20/25, so if you have to get it off, grind the end of a large punch to fit one of the teeth of the nut and use a persuader carefully to break the torque on the nut.

Sometimes we make the mistake of assuming others are familiar with maintenance procedures, so if you are in doubt, get the right tool as you are going to have to torque the nut at the end of the job.

carholme

 

[Moody Blue]

Re: mercury shift shaft removed by accident

If you are going to get into the lower unit you are going to need some specialized tools (buy or make them) and a manual and a seal kit for the lower unit.

There are a couple good threads in this forum on taking the thing apart and the different tools that were used. Use the search function at the top of the page and do some research before you decide to proceed. If at all possible try and get the shift shaft reinstalled without disassembling the lower unit. It can be done.

 

[squejyluigi]

Re: mercury shift shaft removed by accident

i think i'm going to have to go down the route of taking out the gears.
when i look down the shift shaft hole all I can see is two bushing type holes, can't see any geared teeth of which the shift shaft would slot into, should i see the teeth?

 

[CharlieB]

Re: mercury shift shaft removed by accident

Turn the gearcase upside down and shake it, the shift cam should come loose and fall out.