9.5 HP Sportwin 'Pops-Out-Of-Gear' and goes into neutral ...

[bobgritz]

Not all the time but maybe 50% of the time, my 1968 Sportwin jumps out of gear and goes into neutral. This can happen at slow, medium and high speed. Even in reverse! It almost feels like a linkage issue rather than a transmission problem. If I simply hold the shift lever down its fine. Perhaps there is a weak spring, something worn or mis-adjusted linkage. Any thoughts? Here's the link that shows the Lower Unit & Gearcase:
( http://www.marineengine.com/parts/j...anufacturer=Evinrude&section=Lower+Unit+Group ) ( http://www.marineengine.com/parts/j...&manufacturer=Evinrude&section=Gearcase+Group )

 

[Joe Reeves]

Re: 9.5 HP Sportwin 'Pops-Out-Of-Gear' and goes into neutral ...

Drop the lower unit..... four L/U retaining bolts and one (1) 3/8" hex head bolt from the brass shift linkage which becomes visible as the lower unit drops.

Before removing the 3/8" shift connector bolt, check to see that both bolts are securely tight and holding the upper and lower shift rod securely. A loose bolt will allow the rod to slip up/down within the brass connector somewhat.

With the L/U removed, secure the upper shift rod so that it cannot move, then attempt to move the shift lever. If the shift lever moves and the shift rod does not, then obviously some portion of the shift mechanism is either worn or not secured properly.

 

[boobie]

Re: 9.5 HP Sportwin 'Pops-Out-Of-Gear' and goes into neutral ...

Another possibility is worn clutch dog and gears or shift cradle. Any water in the g/c ?

 

[bobgritz]

Re: 9.5 HP Sportwin 'Pops-Out-Of-Gear' and goes into neutral ...

No (noticeable) water in gear case ... but, when I removed the 'fill-check-screw' the lubricant oozed out the hole. The lube was heavy stuff, really heavy, and if memory serves it should be more like a 90W oil/grease. This worries me since it could mean that it has evolved, or de-volved, into something like paste and no longer is soothing the bottom end properly. I'm afraid that either water is at the very lowest point and is pushing the lube upward -or- that it has congealed to the point that it is no longer flowing freely around the gears.

In any case, on the water today I had to continuously hold the shift lever in the down, or forward, position otherwise it would immediately 'pop' out into neutral. I have dodged the inevitable and need to drop the lower end.

The only thing I failed to mention is that the shift lever and all the visible upper linkage (under the cowling) is extremely sloppy and has a tremendous amount of 'play' in it. All the connection points are very worn and the linkage is not tight. However, I doubt this is the problem since, although sloppy, once the gear is in the forward position (worn linkage or not) it should stay there! I'll drop the gc today or tomorrow and update my findings. I have a parts motor so hopefully this thing will cost nothing but time.

(Time is the most precious possession you own and can give another)

 

[bobgritz]

Re: 9.5 HP Sportwin 'Pops-Out-Of-Gear' and goes into neutral ...

Back on the water again. Here's what I found.

The clutch dog (#37 on diagram below) had definite signs of wear. The gears and shift cradle looked good. I was going to take earlier advice and 'flip' the clutch dog 180 degrees so that the rear-gear-side of the dog would service the 'forward gear' but I was lucky enough to have a parts motor so I inspected the dog in that one and found it to be pretty good. While I was in the 'parts motor' gearcase, I noticed that the shiftrod was much harder to operate and upon further inspection I noticed that the shift rod in my 'good' motor was not as difficult to move up and down. I realized that the 'detent spring' (#26) creates the tension on the rod and further inspection revealed that the screw that holds it in place was not as tight as it could be. After tightening it up, the shift rod became firm and my shift lever was no longer 'sloppy' as earlier reported. I suspect that the reason my (and many other) clutch dogs get chipped and worn is twofold;

First, many operators simply have the rpm's too high when shifting into forward or, they go directly from reverse to forward without allowing engine to return to an idle.

The second culprit may be that the detent spring either loses its strength or, as in my case, that the screw (that secures it) simply becomes loose and the shift cradle doesn't stay in the proper forward or reverse position. A hiccup in the motor, or even a sudden wave, can put unusual forces on the prop or propeller shaft which could easily cause the shift cradle to flipflop out of its intended position.

After putting everything back together the shift lever is tight and solid. After my first roadtest it never popped out of forward drive and everything seems seaworthy.

 

[Robert99]

Not all the time but maybe 50% of the time, my 1968 Sportwin jumps out of gear and goes into neutral. This can happen at slow, medium and high speed. Even in reverse! It almost feels like a linkage issue rather than a transmission problem. If I simply hold the shift lever down its fine. Perhaps there is a weak spring, something worn or mis-adjusted linkage. Any thoughts? Here's the link that shows the Lower Unit & Gearcase:
( http://www.marineengine.com/parts/j...anufacturer=Evinrude&section=Lower+Unit+Group ) ( http://www.marineengine.com/parts/j...&manufacturer=Evinrude&section=Gearcase+Group )

I have a 73 Johnson 9.5. Same issues. I just bought a new used bottom end and the same issues. Forward pops out into neutral when going. Odd that it would happen on 2 different bottom ends

 

[racerone]

Not odd at all in my opinion.-----Are the notches on shift rods both lined up with the hole in connecter ?-----Is shift adjusted properly up top on the motor ?-----And lower units are easy to inspect internally.-----And finally you are sure it is not the rubber hub slipping inside the prop ?-----I have more than one of these motors / lower units on the shelf !

 

[Robert99]

Not odd at all in my opinion.-----Are the notches on shift rods both lined up with the hole in connecter ?-----Is shift adjusted properly up top on the motor ?-----And lower units are easy to inspect internally.-----And finally you are sure it is not the rubber hub slipping inside the prop ?-----I have more than one of these motors / lower units on the shelf !

My guess is to adjust upper? Actually this is the third bottom end try now

 

[Crosbyman]

if the GC at not at fault not much left....
side shift connector or.... adjusting the shifter handle on top

 

[racerone]

Did you take these lower units apart before installing them.----So easy and simple to do , ----Well in my opinion it is easy.----First worked on these lower units in 1968.----That was when your motor left the factory !!

 

[Robert99]

My guess is to adjust upper? Actually this is the third bottom end try now

First time it was hitting neutral so hard it ripped the bottom shift rod right out of the brass piece that joins the upper and lower rod. We put a new brass piece on and different bottom end. Rods don’t come apart now but it still jumps out of F and into N

 

[racerone]

Inspect clutch dog and forward gear.-----Find the cause of your issues with this simple set-up !

 

[Crosbyman]

did anyone mess with the philipps head screw in the GC.... maybe the shift dog is loose in the GC ???

 

[Robert99]

did anyone mess with the philipps head screw in the GC.... maybe the shift dog is loose in the GC ???

GC? Sorry?

 

[Robert99]

We just went to buddy’s boneyard and found a different bottom end. Checked the impeller and changed the gear oil and tried again

MOD EDIT: Hi Robert, You have raised an 11 year old thread from its rest. Please review the forum rule about posting to old threads and feel free to start a new thread with your specific information.

 

[Crosbyman]

gc gear case