Stiff shifting

[kwoolard]

Year: 1986
Boat: Tierra Pursuit
Motor: Mercruiser 260
Sterndrive: Alpha One

My friends boat is just about ready to get wet and we replaced the lower shift cable with the new style cable kit because previously the problem was stiff shifting and was engaging the interrupt switch while shifting the motor on the muffs.

Anyway, put the new kit on and put it all back together and the problem is still there. It is really stiff to move the cable in and out of gear, even without the motor running. I've disconnected the cable from the shift plate at the motor and it is stiff to operate by hand. This is the same problem that incurred before replacing the cable and bushings.

The only bushing that wasn't replaced was the lower shift bushing in the lower unit. Could this be corroded and causing this stiffness?

Another thing we thought of was something inside the shift cable cavity in the upper unit obstructing the shift slide from moving.

Thoughts on the next steps?

 

[Don S]

Re: Stiff shifting

If you disconnected the lower shift cable from the engine mount and the shifter is still very stiff, take the shifter out and disconnect the shift cable from the shifter. If the shifter moves ok, you need a new cable, if not you have a shifter problem.
I replace several cables a year from that era and newer. But check it out to be sure.

 

[kwoolard]

Re: Stiff shifting

I did those steps before I replaced the cable, that is what led me to replaced the cable to start with. With the lower cable disconnected from the shift plate the control cable operates smooth and the lower cable is still stiff.

We replaced the lower cable and still have the same problem. Which now is leading to binding in the drive.

Just wondering if anybody has experienced this and could it be the lower shift shaft bushing or something in the gear case.

The upper shift shaft and bushings were replaced along with the cable and slide. Everything is new down to the intermediate shift shaft.

 

[Don S]

Re: Stiff shifting

At the engine, disconnect the cable that goes to the helm control box. Now, try to hold pressure on the cable while someone else tries to move the shift lever. If you can put enough pressure by hand on the cable to cause the shifter to be hard to move, you need a new cable.

 

[kwoolard]

Re: Stiff shifting

The stiffness is in the lower shift cable, not the shifter control cable. We checked both before we replaced the lower shift cable.

The lower shift cable is still stiff after replacement. This was checked by removing the lower shift cable from the shift plate mechanism and operating the lower shift cable by hand.

 

[Don S]

Re: Stiff shifting

Then pull the drive and see what is binding. It's either the shift cable, the shift shaft in the bellhousing, or in the drive.

 

[havasuboatman]

Re: Stiff shifting

Is there any chance you Kinked the new cable feeding it thru the transom?
Also, the lower MUST be roughted correctly to have smooth operation. NO SHARP/TIGHT TURNS
Thru the transom assy, over the top of the Y pipe (V6 and 8), big loop back under the exhaust, up the transom, and the to the top of the motor.
Be sure to use the plastic heat shielding where it passes over the exhaust

 

[kwoolard]

Re: Stiff shifting

Thanks guys.

No sharp bends or kinks, definitely made sure of that while installing. Everything is brand new from the shifter at the helm down to upper shift shaft in the bell housing.

He's going to pull the drive again in a couple of days and i'll check from the intermediate shaft on down.

I was just wondering what it could be in the lower that would cause this. I assume a corroded shift shaft bushing possibly could, other than that, a bent shift crank or shaft???

DonS have you come across binding in the lower unit from your years of experience?

 

[Bt Doctur]

Re: Stiff shifting

Myself, I`v found a bind when the owner didn`t line up the shoes and pulled the unit together with the nuts. This bent the "C" selector in the lower unit. Almost needed vise grips to turn the splined shaft.

 

[Fishermark]

Re: Stiff shifting

other than that, a bent shift crank or shaft???

I had a similar situation - it turned out to be a bent intermediate shift shaft. It would shift fine when taken apart, but as soon as everything was bolted back up - the binding came into play. It can happen when someone tries to remove the outdrive without putting it into forward first. Just something to check when you get it apart.

 

[Don S]

Re: Stiff shifting

You still have to take the drive off and actually look to see what YOUR problem is. Doesn't matter if the problem is common or not. It may be a problem that you are the first to have. But till you get your hands dirty and get the drive off, you will never know.

 

[kwoolard]

Re: Stiff shifting

Thanks, just trying to get some insight before I get back over there again. Too bad he's 40 miles away or I'd keep the laptop right beside the tool chest.

Can you remove the shift crank if it is the issue without completely disassembling the lower unit? Seems like I read somewhere you could pull it out through the bushing hole.

 

[Bt Doctur]

Re: Stiff shifting

Shift shaft but not the shift crank.

 

[kwoolard]

Re: Stiff shifting

Turned out to be some minor crud in the shift cable slide cavity in the upper unit. Was just a very thin layer of some dried up tacky film and dust. Caused the slide to have too much friction. cleaned it out and shifts like a champ now.

thanks for your help!

 

[heycods]

Re: Stiff shifting

NCFL this in inboard section, check Merc. outboards