Shift Cam came out on my 9.9

[Asaracing21]

I have no clue on how I managed to do this but when i removed the water pump and yes the c clip is on the shift rod correct, the shift cam came out. I know which way it goes by the diagrams I have but I have no idea on how to re-install it. I push down and it clips but when you pull up it pops out again. I have read something about taking a screw driver down to it and pushing it back towards the prop? Anyone know how to install it properly? I appreciate all the help everyone has given me on these forums....

*Motor 1996 Mercury 9.9 2 stroke

 

[MH Hawker]

Re: Shift Cam came out on my 9.9

Their is a very small square slot in the in the very front of the gear cluster and housing that the shift cam fits into, once it pops out of place it is very hard to get back in unless you take the water pump back apart and remove the housing so you can see it and push it back in place, then push it all the way down ( a flash light really helps )and reassemble and try not to move it any at all, the total travel on the cam is only about 3 / 4 of a inch before it pops out of place. This is one of those dont ask how I know about this thing. I bought a really messed up 1996 motor a few years ago.

O and be very sure to adjust the shift rod distance before you put it back together.

 

[Asaracing21]

Re: Shift Cam came out on my 9.9

I can see it pop back down in place but its in neutral at the moment and I'm pretty sure the shift rod comes up for forward gear? If I pull even a little bit it pops out.

 

[Hoosmatroos]

Re: Shift Cam came out on my 9.9

I think you mean your shift shaft came out. Your shift cam is still in the lower unit.

Please check from here (page 6-25) how to reinstall it. Don't forget to read it all, also the adjustment on page 6-34.

Boatinfo - Mercury Service Manual for 6-8-9,9-10-15 hp

Not to difficult but read it carefully. Good luck.

 

[MH Hawker]

Re: Shift Cam came out on my 9.9

I can see it pop back down in place but its in neutral at the moment and I'm pretty sure the shift rod comes up for forward gear? If I pull even a little bit it pops out.

The step distance between F, N, R is 1/4 between shift steps, so when putting it back together is is easier to push it as deep as it will go. The C ring on the shift shaft is to prevent over travel and keeps the cam in place after the water pump is installed. After the water pump is installed then you move it into neutral and adjust the shift shaft distance as per the above chart.

 

[MH Hawker]

Re: Shift Cam came out on my 9.9

I think you mean your shift shaft came out. Your shift cam is still in the lower unit.

Please check from here (page 6-25) how to reinstall it. Don't forget to read it all, also the adjustment on page 6-34.

Boatinfo - Mercury Service Manual for 6-8-9,9-10-15 hp

Not to difficult but read it carefully. Good luck.

On this motor the shift cam is a 3 stepped wedge shape on the end of a threaded rod and it is very easy for it to pop out of place. it is held in place by a C ring on the shaft that is under the water pump housing and when you remove the water pump housing it often pops out of place.

 

[Asaracing21]

Re: Shift Cam came out on my 9.9

On this motor the shift cam is a 3 stepped wedge shape on the end of a threaded rod and it is very easy for it to pop out of place. it is held in place by a C ring on the shaft that is under the water pump housing and when you remove the water pump housing it often pops out of place.

Alright ill push it down install new seals on my water pump and this shift rod is a no brainer screwed all the way in the shift cam turned back just so it's facing the correct way for the top of the engine. O are these holes on the shift cam where it pops into place? Just so I know don't screw the rod into those holes...

 

[MH Hawker]

Re: Shift Cam came out on my 9.9

The cam has a flat back surface and the stepped front the flat surface goes toward the very front of the LU and the stepped surface goes toward the gear cluster and the back of the LU where the prop goes. The shift rod goes into the top of the cam and threads in. Then you push it dond as fat as it will go, and its not all that much. It has about 3/4 of a inch of total travel. Once that is in place then you install the water pump and assorted parts completely. The last step is to set the shift cam travel and you do that by turning the shift rod and making a measurement front the front top of the water pump housing bolt to the shift rod pin eye, as shown in the picture. You may need to click on the picture a few times to make it big enough to see it.

 

[MH Hawker]

Re: Shift Cam came out on my 9.9

The cam has a flat back surface and the stepped front the flat surface goes toward the very front of the LU and the stepped surface goes toward the gear cluster and the back of the LU where the prop goes. The shift rod goes into the top of the cam and threads in. Then you push it dond as fat as it will go, and its not all that much. It has about 3/4 of a inch of total travel. Once that is in place then you install the water pump and assorted parts completely. The last step is to set the shift cam travel and you do that by turning the shift rod and making a measurement front the front top of the water pump housing bolt to the shift rod pin eye, It should be in the neutral position when you adjust it. Its shown in the picture. You may need to click on the picture a few times to make it big enough to see it.

View attachment 215257

It sounds a lot more complicated than it really is and I wish that I had taken picture last year when I had mine apart. That is the easy part. On mine at least it was a real PIA to get the water pump tube back in place due to the fact that my motor is mounted on a pontoon boat. I ended up buying a bore scope to get the tube in place. But if you run into problems let me know.

 

[Hoosmatroos]

Re: Shift Cam came out on my 9.9

I did made some pictures on a repair for a customer this year. Will put the pictures her in two hours.

 

[Hoosmatroos]

Re: Shift Cam came out on my 9.9

Oke, the promised pictures.

 

[Hoosmatroos]

Re: Shift Cam came out on my 9.9

And some more

 

[Asaracing21]

Re: Shift Cam came out on my 9.9

And some more

Thank you for the pics I will upload them when I get a chance my phone apparently won't.

 

[Rscook]

Re: Shift Cam came out on my 9.9

And some more

I know this thread is old but can you tell me which direction both seals face when installing in the plastic housing. Also do I put the rtv on after all the bolts are tightened? Do you know where I can download the repair manual? Appears the link above is no longer active. Thank you