Shift Shaft Lever Replacement

[ngoodart]

Good friday to all,
I have another thread going but that is for a different issue, so new issue new thread. After replacing my lower sift cable last night I went to check the placement of the shift shaft to make sure they would line up and be in forward to re-mount the drive to the gimbal....Much to my dismay I noticed that the top part of the **** lever on the lower unit is broke completely off:facepalm:
So now I get to seperate the drive and replace that, Im going to be ordering OEM part# 62104-1 and while I have the lower off going to replace the impeller and housing while Im at it just to be sure. Are there any suggestions of things to look for while I have the drive apart, the manuals aren't very clear on how to replace this piece, Im sure I can figure it out but just thought that I'd ask.
Thanks

 

[Don S]

Re: Shift Shaft Lever Replacement

What are we working on?

 

[ktbarrentine]

Re: Shift Shaft Lever Replacement

What drive are we working on? What manual are you using? (the "good" ones are found in links on this forum - see the stickys in the adults only area) A pressure test before splitting the drive (after oil removal) and after reassembly is always a good thing to do. Replacement of the intermediate shift shaft is fairly intuitive and straight forward. Of course, remember to place your shifter full fwd (not so important for your particular removal, since the shoe apparently is broke off, but important all the same for reinstallation). You'll need to make sure the lower shift shaft (I am assuming this is a pre-genII alpha or earlier - your shift shaft part number points to that, at least). is in fwd and prop is locked CCW for re-mating the drive halfs (and don't forget to re-install the stainless washer on the lower shift shaft!).... Pretty fundamental stuff. Keep the forum posted and best of luck!
Any clue as to how that shoe got broken?

 

[ngoodart]

Re: Shift Shaft Lever Replacement

I am working on a 84 I believe its an Alpha 1 Drive S/N 6748725. I am using the Manuals that Don provided me in my other thread. Im ordering that Shaft, new impeller and seal kit for the drive. My guess as to how it got broken is the PO attempted a shift cable "repair" and didn't have the drive in forward when re-mounting and it got broken. I plan on pressure testing after re-assembly of the lower to the upper. Thanks for the help guys, is there anything else that I should check while I have it apart to forego having to take it apart agian to replace something?

 

[ngoodart]

Re: Shift Shaft Lever Replacement

Also, Can you point me in the right direction for the water impeller kit, it appears as though I would need 18-3320 Just want to make sure I order the right ones.

 

[Don S]

Re: Shift Shaft Lever Replacement

Make sure the upper shift shaft in the bellhousing isn't all bent out of shape, or you could end up breaking your new lower shift shaft.

 

[ngoodart]

Re: Shift Shaft Lever Replacement

Thanks Don, I will double check that It looked pretty good when I was cleaning it all up lastnight. Is 18-3320 the right water impeller kit for my drive?

 

[stonyloam]

Re: Shift Shaft Lever Replacement

, the manuals aren't very clear on how to replace this piece, Im sure I can figure it out but just thought that I'd ask.

You just pull the pin (23) out of it and it should pull right up out. Illustrated Here: http://www.mercruiserparts.com/Show...0065.png&inbr=2203&bnbr=60&bdesc=BELL+HOUSING

 

[ktbarrentine]

Re: Shift Shaft Lever Replacement

Iboats has the impeller kits, or you can try:

www.mercruiserparts.com
www.crowleymarine.com
www.amazon.com

just to name a few sources.

 

[ngoodart]

Re: Shift Shaft Lever Replacement

Thanks guys, I appreciate it. I found the impeller kits on Iboats, just not 100% sure on how to decipher the S/N deal:
MR/ALPHA I S/N 6854393-D594568 uses P/N 18-3320 9-48307 This is the one I wat right?

 

[ktbarrentine]

Re: Shift Shaft Lever Replacement

Very important to match the particular kit with the exact drive you have... so many differences over the years.... I find a good resource at www.crowleymarine.com and www.mercruiserparts.com because you get the exploded view of "your" drive with the part numbers... Then I cross ref to other sources for best deals (like free shipping,etc.). Also, different kits have a differing array of included parts. I like the kits with the lower pump base, pump housing, impeller, key, and the various seals/gaskets/plates.

Others can chime in on their techniques...

Best of luck!

 

[ngoodart]

Re: Shift Shaft Lever Replacement

Well it looks like the UPS man will be bringing me more presents today, All my ingition tune up parts will be here today. I did verify the water pump kit was the correct one for my drive. I will re-post if I have any questions when I get the drive apart. Thanks for the help guys....The admiral is begining to get antsy, and my 4yr old little admiral loves to work on the boat with me. Nothing like seeing my little angel with oil and grease to her elbows from cleaning out the gimbal housing..... Makes me happy
Thanks agian for all your help I appreciate it.

 

[ngoodart]

Re: Shift Shaft Lever Replacement

Well, I thought that I would update this post... I got the drive back together last night an interesting experience that was LOL.
Summary of what I did.
Seperated drive to replace broken shift lever, installed new impeller housing, and every single seal and o-ring I could find in the lower. Throughly cleaned the gearing and inspected everything looked in really good shape. cleaned out the upper drive inspected all the parts agian looked really good sape had a few orings that were damaged from the PO installation techniques. Not a big deal though cleaned out the gimbal and greased all the zerks, cleaned and inspected the splines all is well there lubed up and checked allignment spot on there. Now comes the juggling act..... I have come to the conclusion that you need 3-4 arms to do this easily.LOL But I got it together bolted up and manually moving the shift cable it shifts in and out of gears smoothly very little effort.. Nice....Next up Pressure tested drive.... made a set up similar to what I have seen on the site here and pumped her up to 15 PSI... and she held that all night.. Read 14PSI this morning. Swapped over to the Vaccum and pulled a vac on it, we will see how that holds after I get back home tonight.. Whooofta That was alot of "fun" But for my first experience servicing an outdrive I think I did pretty good The manuals are essential as the seal kits are very generic and have some gaskets and orings that I didn't need for my water pump....... Now to just get that idle adjusted from my other thread and I'll be ready to splash!
Thanks for all your help guys I appreciate it!!!

 

[ktbarrentine]

Re: Shift Shaft Lever Replacement

Sounds good so far! Just curious why you opted to do the pressure/vac test after you put the drive back on. A leak would mean having to pull it off again; also, if you see a pressure drop (leak) you'd want to do a soap-bubble test of the accessible seals, all of which arent accessible with the drive on... Sounds like you may have dodged the bullet! How much vacuum do you use for your vacuum test? too much can be bad...as the seal on the gear-end yoke is not really designed to hold in that direction, but I have successfully tested it (and the rest of my drive) to about 5 inches. Typically I pressure/vac test the halves separately, then join and check again (checking the quad ring). Yeah, more work, but it is fun.
Good luck on the splash!