Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990)

[denhajm]

Hello,

Today I changed the impeller in the lower unit of my Alpha 1. I had the lower unit in gear during reassembly so that by slightly turning the propeller I could align the spline shafts on the drive as I was sliding the lower unit up into the upper unit.

First, I tried it with the lower unit in forward gear (and the throttle/gear positioner by the drivers seat in the forward setting. Once I got the lower unit together, I found that I could not pull the gear shifter back past the neutral position--something was keeping the cables from moving back into reverse gear.

After some head scratching I tried the opposite. Removed the lower unit, put the gear shifter by the driver seat in reverse, put the lower unit in reverse and kept rotational load on the prop to keep it in gear as I attached the lower unit to the upper unit. Again, same problem, only the opposite way. The throttle/gear positioner, which was in reverse, could be pushed forward to neutral, but not past neutral into forward gear.

There must be something I'm missing--some technique for getting this right? This is all with the boat in a garage--I've not started the engine since replacing the impeller, but prior to removing the lower unit today, it would easily shift from neutral to forward, to neutral and into reverse all while sitting on the trailer in the garage (dry, not running).

Any tips?

thanks,

Jason
1990 Sea Ray 200BR

 

[trevtt600]

Re: Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990

I hate to say it, but you need to separate your drive again. You must have accidentally moved a tooth or two on your shift shaft in the lower unit. Once you separate the drive, move the shift spline till the prop is lock in forward gear (prop moved couter-clockwise). Then make sure the lower shift shaft is facing straight forward when you put the drive halves back together and the prop it still locked in forward gear. Make sure your shifter is in full forward and reinstall drive. Hope this helps.

 

[dubs283]

Re: Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990

it sounds to me as though when you think you are in fwd with the gearcase assy, you are actually in rev - and vice versa

when the gearcase assy is in fwd gear, the propshaft will lock counter clockwise, i.e. you rotate the prop counter clockwise to rotate the driveshaft when lining up the splines upon reassembly

so, in rev you would rotate the prop clockwise to line up the splines

this is why it is a good idea to pull the entire drive assy when servicing the water pump, it easier reassmbling and it allows you to do some other necessary maintenance too

 

[stonyloam]

Re: Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990

Yeah Dubs is right, if the gearshift is jammed, then the intermediate shift shaft went on "off a spline" and you were in reverse rather than forward when you put it together. When you shift from forward to reverse the shift shaft tries to rotate counterclockwise, and it is already all the way counterclockwise so it jams. Here is how to fix it: Drop the lower unit and rotate the lower shift shaft (small splined shaft) all the way clockwise, and rotate the prop shaft COUNTERCLOCKWISE until it locks. You are now in FORWARD. Put a bungee on the prop to hold counterclockwise pressure on the prop to hold it in gear and put it back together, making sure that the ss washer is in place on the lower shift shaft and the intermediate shaft is pointed straight ahead. I think you put it together and held it in place using clockwise pressure, which is in reverse. I know that doesn't seem right but if you think about it with the engine turning the prop clockwise, the prop would put pressure on the gears in the CCW direction. Good luck.

 

[brnschoneck]

Re: Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990

y it can be very tricky i must say after spending about 4 hours on mine i couldnt get it by myslef so i had to have somepne help me so i could stick my hand up inthe back making sure the splines lined up and went togethter having another hand may help also ...be patient youll get it !!!

 

[denhajm]

Re: Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990

It is together and working properly now. I believe when I thought I had the prop in forward gear, I actually had it in reverse. After following the instructions above (and Don's instructions for changing impellers) everything is together and the throttle arm smoothly goes full forward to full reverse. Looking forward to getting her fired up once I take care of a few more items. Thanks for the help.

 

[johnlewi]

Re: Trouble with shifting after changing impeller in lower unit - Alpha 1 Gen 1 (1990

I hate to say it, but you need to separate your drive again. You must have accidentally moved a tooth or two on your shift shaft in the lower unit. Once you separate the drive, move the shift spline till the prop is lock in forward gear (prop moved couter-clockwise). Then make sure the lower shift shaft is facing straight forward when you put the drive halves back together and the prop it still locked in forward gear. Make sure your shifter is in full forward and reinstall drive. Hope this helps.

hi all was good then al of a sudden i was having problem getting into reverse, when i took bottom in off i see shift spline is just hanging is that normal or should shift spline stay up in place, or does it get pushed up when u put bottm end on thanking u in advance for your time