Bent Shift Linkage on Mercruiser/SE Outdrive

[naturalone]

I have been reading the site for a few days and hope I can explain my question correctly.

1986 21' Sea-ray Sorrento
260 HP Mercruiser Engine
Drive used to be Alpha One but was replaced with SE106 4-5 years ago.

Hopefully that's enough info on the boat.

My brother-in-law put the new (full drive, upper and lower) Sterndrive Engineering outdrive on the boat 4-5 years ago. The boat worked fine until last year. Now it won't shift out of forward gear using the remote control. I can manually turn (with my fingers) the shift linkage and shift the drive from forward and reverse. The shift rod (where it connects to the bell housing slot/linkage) from the drive appears to be bent about 5 degrees to port from directly forward. The slot of the linkage coming from the bell housing appears to be wider than it once was. The combination of the two bent pieces means that there is considerable play (1/8"-3/16") between the two linkages.

This is what I think I know:

1-Drive was forced on/off without having shift linkages aligned. I.E. not in forward gear.
2-Lower shift cable is broken, seized, or somehow no good. Otherwise I would need a crescent wrench to shift the drive manually.
3-All bellows or any other parts that would require the removal of the bell housing are original or 10+ years old.

This is what I think needs to be done in addition to fixing the linkage issue:

4-Replace lower shift cable.
5-Replace all bellows.
6-Inspect Gimbal bearing and replace if needed.

My questions are what to do about the bent linkages.

Upper Linkage/ 7-Replace the entire bell housing or just the bent linkage? 8-How difficult is replacing linkage only?

Drive linkage/ 9-Can the rod be straitened/fixed without opening up the drive? 10-If not, how difficult is replacing the rod?

I know a service manual would likely answer these but I'm just looking for a rough estimate of where I stand before I spend money on this boat.

Additions/corrections to "what I think I know & should be done" would be appreciated as well.

Thanks for the help.

 

[stonyloam]

Re: Bent Shift Linkage on Mercruiser/SE Outdrive

Upper Linkage/ 7-Replace the entire bell housing or just the bent linkage? 8-How difficult is replacing linkage only?

Drive linkage/ 9-Can the rod be straitened/fixed without opening up the drive? 10-If not, how difficult is replacing the rod?

Upper shift shaft is easy (maybe). Simply remove drive, remove the upper shift shaft arm (screw and pin) from shaft, the shaft drops out. If you are replacing it anyway and you can't get the arm off, just cut it. When you replace the upper shift shaft also replace the shift shaft bushings and seals with the "new" style if not already done.

I think there is just a pin holding the intermediate shaft in the upper (driveshaft housing). #21 & 22 here: http://www.mercruiserparts.com/Show...0065.png&inbr=2203&bnbr=60&bdesc=BELL+HOUSING good luck.

 

[Fishermark]

Re: Bent Shift Linkage on Mercruiser/SE Outdrive

Welcome aboard!

This is a classic case of someone trying to remove the drive without everything being in forward gear. But as Terry mentions, it is easy to replace the bent parts.

If you are replacing it anyway and you can't get the arm off, just cut it.

I recently changed mine and the pin would not come out easily. (It is supposed to simply screw out, but corrosion can make that a challenge). I read where you can break the upper arm very easily with a sharp blow from a cold chisel. I tried it and sure enough - worked great. A good lick right at the point where the pin screws in will do the trick.

Just buy a new shift arm and shaft. Not terribly expensive. You might even be able to bend the upper shift shaft back - but it doesn't cost too much. If there is any doubt I would suggest buying a new one.

 

[Fishermark]

Re: Bent Shift Linkage on Mercruiser/SE Outdrive

By the way, it is a good idea to go ahead and replace the shift shaft bushings while you are there with the new style. Easy to do while you are replacing other things anyway. Here's mine with the new bushings installed:

Here it is with the shaft and new arm back in place:

 

[naturalone]

Re: Bent Shift Linkage on Mercruiser/SE Outdrive

Thanks for the advice guys. I just got home from work and I'm going to start on this project tonight. Once I get the drive pulled and the bellows off I'm going to inspect the Gimbal bearing. Hopefully that will give me a complete parts list and project scope. Anything else I should be planning on replacing besides the new bushings and seals, both linkages, all bellows, gimbal bearing, and lower shift cable?

 

[stonyloam]

Re: Bent Shift Linkage on Mercruiser/SE Outdrive

Anything else I should be planning on replacing...

Might as well do the impeller.