OMC Cobra wont shift into gear

wsparadise

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May 18, 2006
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Well, out running a 5.7L OMC cobra today and while at about 3000 rpm and 35mph heard a whirring, by the time I started slowing down the boat kicked into neutral. Upon stopping it will not shift into fwd or reverse. Feels like it is trying to shift but no power. Prop seems OK, not spun, Cables seem OK. When I put it on the trailer I put it in gear and can still rotate the prop and it feels like the gears are meshing but can rotate pretty freely for being in gear. Same for fwd and reverse, gears are meshing but obviously not engaged with the engine otherwise I could not turn the prop/engine by hand. Any ideas?<br /><br />Thanks, in advance,<br />Bill
 

Don S

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Re: OMC Cobra wont shift into gear

If the prop is ok (and I am not sure you tested it correctly) then your next bet would be to check the coupler. A spun coupler can act just like that if the splined portion lets go of the rubber part of the coupler. or the splines could be stripped out of the coupler.<br />Look behind your engine where the shaft enters the coupler. Do you see any metal shavings or burned looking rubber on the coupler? <br /><br />
I put it in gear and can still rotate the prop and it feels like the gears are meshing but can rotate pretty freely for being in gear.
Does it feel the same as when everything worked properly???
 

wsparadise

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Re: OMC Cobra wont shift into gear

Thanks so much for your thoughts, a rubber coupler between the engine and the outdrive sounds like it makes sense. I think if the hub were spinning it would not spin by hand and thus I would not be able to spin the prop when in gear. I will have to take it in likely to have it checked out. I am fairly new to Outdrives. By the way, how do you check for a spun prop?
 

wsparadise

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Re: OMC Cobra wont shift into gear

I will look for any burned looking rubber or metal at the rear of the engine in the morning. I did not try and turn the prop in gear while on the trailer before this so I don't have any frame of reference. Thanks again for your thoughts. Does the motor have to be pulled to replace the coupler or just the outdrive? I had some guy pull the outdrive recently to check for leaks and I dont think he used an alignment tool to replace. Could that have caused this?
 

wsparadise

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Re: OMC Cobra wont shift into gear

No evidence of burned rubber in the stern behind the motor, also no metal chips that I can see. I am a little baffled. I suppose the U-joints could have broken but they looked in good shape a week ago when I had a guy remove and inspect the outdrive.<br /><br />Don, Thank you for your time and advice. It looks like I will have to take it to a shop. Anyone know the going labor rate for a coupler replacement?
 

seahorse5

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Jan 24, 2002
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Re: OMC Cobra wont shift into gear

Did someone fill the gearcase recently? If done incorrectly, the upper gears do not get lubricated and they will self destruct after a short time, giving you a neutral-like situation.<br /><br />Others on this newsgroup have had this problem.
 

wsparadise

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Re: OMC Cobra wont shift into gear

Yes the gearcase was just filled by some local guys here who have a mobile marine repair biz. I wasnt sure about them but took a chance. I guess the proof will be in what is actually wrong with it when I take it in.
 

seahorse5

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Re: OMC Cobra wont shift into gear

Bill,<br /><br />Remove the 4 bolts on the top of the outdrive and remove the cover. Have a camera and a credible witness ready in case you are going to pursue this legally.<br /><br />Chances are there will be very low or no oil visible (check the dip stick first) and you will see the teeth of the upper gears "flared out" like they were melted and pushed outwards.<br /><br /><br />You will need a copy of a factory service manual or owner's manual that shows how the gearcase should be filled correctly. It should be filled from the middle screw hole, not the bottom hole, until it reaches the correct dipstick level.<br /><br />If someone filled from the bottom hole instead of the middle hole, they would leave an airpocket in the outdrive even though the dipstick showed an oil level. As soon as the motor was run, the oil would circulate and drop into the air pocket depriving the upper gears of lubrication, and expensive damage occurs.<br /><br />The factory manuals say to run the motor a few minutes after refilling and then recheck the oil level to help prevent problems like I think you have.<br /><br />Also check your invoice and with the "mobile mechanic" to see what type and brand of oil was installed. The drive does NOT take a hypoid 90 or a 75W-90 oil like some others do. The only oil approved for it are the OMC/BRP products such as HI-Vis or UltraHPf.
 

wsparadise

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Re: OMC Cobra wont shift into gear

Commander, you nailed the problem. Thank you for the advice. I pulled the dipstick from the top of the outdrive and no oil was present. I did have a witness and took pictures. I then pulled the cover and just as you thought, the top gears are completely worn down. Also, there is no evidence of any oil looking into the top gear cavity. I have pics if anyone is interested. At least now I know I am dealling with a new upper gear set and who knows what else. Does anyone know what the procedure is in a case like this? Does the lower unit have to be flushed or torn down for inspection? Any help from experience would be appreciated as I am probably going to have to go after the mechanic and need to know what I am getting into for repairs. At this point I don't really trust them to work on my boat so my preferred option is to have it repaired and send them a bill (or small claims court).
 

cobra 3.0

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Re: OMC Cobra wont shift into gear

What a bunch of hacks! <br /><br />Moral of the story: Best to do simple things yourself and double check everything else that someone else does for you.
 

lakelivin

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Re: OMC Cobra wont shift into gear

I had a similar experience. I gave the shop that did the oil change a chance to work it out (they were neighbors). They appeared amiable, but I got screwed and we ended up in small claims court. I won, but was awarded only half of the total cost to get the upper fixed (not to mention the stress, hassle, and loss of use involved with the whole affair, which was worse than the money I lost).<br /><br />here are some suggestions that might help.<br /><br />First, DON'T add or drain any oil yet yourself. Note hours on the boat when they serviced it and after you discovered the damage (I assume it was either almost immediately or after very low hours, true?)<br /><br />I'd get it to a shop with alot of Cobra experience (specifically one with OMC certified mechanics) and start compiling evidence you can use in small claims court. <br /><br />1) Have them inspect the upper gearset and document what they find.<br /><br />2) Have them drain the oil, measure, and document how much was in the drive. (my 4.3L should have had 64 ozs; there was probably 40 ozs or less in there when it came bck from the shop). If the amount of oil is significantly less than the spec'd amount they probably filled it like a Merc, i.e., filled from the bottom drain plug to the level of the middle fill plug, leaving almost no oil in the upper. If the level is low but not to that extreme, they probably filled from the bottom drain plug to the top check hole, but left an air pocket which would work it's way to the upper unit & still trash the gears and/or bearings. <br /><br />3) Check your invoice from the "mobile mechanic" and see if it lists the amount of drive oil they charged you for; compare against specs for your drive. Maybe you'll get lucky. If they list an amount significantly less than specs, you shuld be golden in court. <br /><br />4) If the oil the shop drained is lower than spec, try to get the shop to write a statement on company letterhead documenting that the damage is consistent with an improperly filled (underfilled) outdrive. If you can get them to accompany you to small claims court, great; (I suspect this is unlikely, and you'd have to pay them for their time). If not, have them get the statement notarized.<br /><br />5) Have the OMC shop save any metal filings stuck to the magnetic drain plug (or that they can fish out of the bottom of the unit) for documentation.<br /><br />6) Get an OEM OMC Service Manual for your Drive and take it to court. Mark/ highlight the portions where it tells how to fill the outdrive and what can happen if you do it incorrectly. If you can't get your own copy, find one to borrow and copy the relevent pages (including the manuals cover). There are several places where this is noted, including a specifically marked paragraph warning about drive damage if you fill the drive incorrectly. I'd mark/ copy each place it mentions it in the Service Manual to emphasise the point to the judge.<br /><br />7) This could be very helpful. Take a friend along with you (someone willing to go to court & serve as a witness) to talk to the 'mobile mechanic' who actually did the oil change. Tell him you're having problems with the outdrive and ask him if he filled the drive from the bottom plug. Would be nice if the boat was there so he could actually point to the drain plug, but perhaps you could get a picture of the drive and have him point to the plug he filled it from. If he's unfamiliar with Cobras (and it sounds like that's the case), chances are high that he'll reflexively tell the truth (that he filled from the drain plug, which would be correct for a Merc, but not a Cobra). Your friend can verify his response in court if need be so it doesn't turn into a 'he said/ she said' standoff.<br /><br />8) Ask the OMC shop about possible damage to the lower unit from metal shavings, etc. I don't know if this is much of a risk - others here should be able to answer this question. If there is any risk, I'd have the shop inspect the lower unit to make sure there's no collateral damage to it as well.<br /><br />That's about all I can think of at this point; I wouldn't let the 'mobile mechanics' fix the boat after an incident like this one. If they offer to pay for repairs in order to avoid court (and perhaps a negative report to the Better Business Bureau), I'd go ahead with all of the steps I listed anyways in case they change their tune before it's all done. <br /><br />Good luck; I hope you're in for less of a hassle than I experienced! <br /><br />ps if you're interested, here's the link to my post from 2004 about what soulnds like a very similar incident. <br /><br /> http://forums.iboats.com/cgi-bin/ubb/ultimatebb.cgi?ubb=get_topic;f=24;t=008398#000000
 

wsparadise

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May 18, 2006
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Re: OMC Cobra wont shift into gear

Thanks LakeLivin, Very Sound Advice indeed. I really appreciate you spending the time to document the above. I have thought through al lot of this and am planning on taking to an OMC certified dealer. I did think of having the mechanic document the drive's ability to hold pressure but did not think of the shavings and measuring the oil (as well as the statement). I agree, I do not want these guys near my boat as I think they will do even more damage and cause a lot of headaches and wasted time. Spoke to a reputable OMC repair facilty today and they suggested the lower end must be disassembled and inspected. Probably only needs new bearing and seals and not gears but it must be cleaned out and checked. I will update this post when this all settles out. I just have to keep repeating... this short term.. boating is a lot of fun in the long run :)
 

lakelivin

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Re: OMC Cobra wont shift into gear

Bill,<br /><br />At least you've got a clear plan of attack. Wish I knew then what I know now!<br /><br />Keep us informed along the way (e.g., how much oil is in the drive, where the mobile mechanics say they filled it from, etc.).<br /><br />Again, good luck.
 
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