Problem with my Upper Shift Shaft shifting upwards?

[jobsonsplace]

I have a 2006 Alpha one gen2 drive on which I have removed the lower gear housing to replace the Impellor.

With the throttle in forward gear and the Impellor replaced I lined up the gear housing below the Drive shaft housing and mated the 2 halves making sure the shift shafts were alligned etc.

What has caused me concern and I need help about is to do with the Upper shift shaft assembly.

Normally the saddle area of the U.S.S sits tightly over the RT angle section of the lower shift shaft, coupling both together for a gear change to occur.

My problem is if I push gently upwards against the U.S.S the shaft can raise vertically by 0.5cm which allows the upper and lower sections of the shaft to disengage, permanantly stopping me from engaging forward or reverse!

Urgent advice on this would be most welcome as we are due to launch next week. I don't want to find the coupling disengaging randomly.


The Drive shaft Housing has a serial no ow808552 and all the U.S.S bushes are fine.

Regards
Paul.

 

[cr2k]

Re: Problem with my Upper Shift Shaft shifting upwards?

Find the washer you left out and replace it.

Hint: It goes under the shift shaft on the lower half of the drive and holds it up in the proper position.
If you can't find it go buy the proper one. Any old washer won't work.

 

[Don S]

Re: Problem with my Upper Shift Shaft shifting upwards?

Find the washer you left out and replace it.

Hint: It goes under the shift shaft on the lower half of the drive and holds it up in the proper position.
If you can't find it go buy the proper one. Any old washer won't work.

He has a Gen II, no washer, different setup completely.

The only thing that can cause that much play is a worn out bellhousing or bushing in the bottom of the bellhousing has a problem.

 

[Pete104]

Re: Problem with my Upper Shift Shaft shifting upwards?

The shift shaft "bushing" in the lower keeps everything true & square.

The shift shaft bushings in the bell housing, top has the seal & the lower 1 has some play in it. Enough to feel it if move it side to side by hand, .060"-.070" maybe.

 

[jobsonsplace]

Re: Problem with my Upper Shift Shaft shifting upwards?

The drive is no more than 6 yrs old with very little wear and tear and Side to Side movement is negligible.

A area which has caught my eye is from a page in the service manual (4b 35), it suggests that the Upper Shift Shaft is connected to the U.S.S lever, and it mentions a U.S.S lever screw.... If the screw was lose would the U.S.S be able to move vertically, causing my problem?

Do you know if the lower bush can, if it's a poor fit, rise up allowing the U.S.S more verticle movement?

 

[Don S]

Re: Problem with my Upper Shift Shaft shifting upwards?

Pull the drive and look.