Shift Assist and adjustable stud

[RonVF]

1988 Sea Ray, 3.0 Merc.
I have been attempting to adjust my shift cables but I don't think I am either doing it correctly or I need to replace the lower cable.
When I follow the instructions by the book and I set the adjustable stud on the shift plate to the lower position the drive will not engauge into reverse and the engine will cut out. If I move the adjustable stud to the top or closer to the connector for the control cable then it will go in and out of both forward and reverse.
Can anyone tell me if this sounds like a stretched cable and it needs to be replaced? Is it okay to operate with the adjustable stud at the other end of the slot? I just bought this boat and I found the ignition cutout switch had been disconnected, probably because the engine cuts out completely.

I have read a bunch of post and reviewed the manual on replacing the cable but I am still a little in the dark.
Do I need special tools as is outloned in manual #6? One for removing the old cable or will a deep socket work? and what about crimping the clamps on the bellows or with they be regular clamps? Are there any other items should I be conserned about needing special tools for? I am still unsure about the lower cable, do I cut it and if so were. manaul 6 is a little unclear.

Any help would be greatly appreciated.

Thanks,

RonVF
Halfmoon, NY
1988 Sea Ray 180 Open Bow
3.0 Merc

I just pulled the drive, now I have more questions.

The lower cable is stiff so I will plan on replacing it. I also found what I thought was gear oil when I pulled the drive, however it is gray and not the blue-green like in the drive. I was afraid it might be the oil seal behind the universal. The bellows is packed with grease so maybe it is water mixed with the grease??if so were would the water have come from? I will inspect and replace the bellows if they require.

Thanks again

 

[achris]

Re: Shift Assist and adjustable stud

Hello Ron,

The shift cable replacement sounds like it should fix the shift problems.. Don't need any special tools, just a tap for cleaning the threads in the bell-housing for the new shift cable..

Gray grease in the bellows does sound like water's getting in. Check the bellows thoroughly. It's easy to miss a small hole...

At the same time I would also replace the upper shift shaft seal (in the exhaust cavity of the bell-housing), as that's probably the reason for the shift cable failure in the first place. For the clamp on the shift cable bellows, I use a small cable tye. Cut the end off nice and neat and make sure it's doesn't interfer with the uni-bellows.

Good luck.

Chris..................

 

[RonVF]

Re: Shift Assist and adjustable stud

Chris,

Is the upper shift shaft seal different from the shift cable bellows?
If so were is it located and how do I get to it.

Thanks,

RonVF

 

[Don S]

Re: Shift Assist and adjustable stud

Below is a link for the OEM service manual. Should Answer all your questions.

http://www.boatfix.com/merc/Servmanl/6/6covr3.pdf

 

[RonVF]

Re: Shift Assist and adjustable stud

Thanks for the helps guys.

I replaced the cable, there was a kink in it down on the end. All is smooth now, at least in the garage. I hope to get here to water Thursday and check to see if my adjustments are good..


Thanks again,

RonVF
Halfmoon, NY
1988 Sea Ray 180 OB