Shift Issues After Shift Rod Bushing Assembly Replacement

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Jul 9, 2021
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Hey all. I removed the lower in my 1992 alpha 1 gen 2 to replace my shift rod bushing assembly. Unit was in forward for removal, but upon replacement and bolting up I found the prop spins freely in reverse and forward. I can hear the dog clutch moving but there is not full engagement with lockout. Thoughts?
 

Bondo

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Ayuh,..... Welcome Aboard,..... My guess is, you didn't hold the lower unit in forward gear, when ya stabbed it back into the upper,.....

I use a bungee strap from the cav plate, 'round the prop shaft, to the cav plate to hold tension on the dog clutch to keep it in forward gear,.....
 
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Jul 9, 2021
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That was my suspicion as well so I dropped the lower last night and ensured engagement when reinstalling. Prop appears to engage and lock out but it looks like I may need some cable adjusting. Going to muff and run today to confirm and report back.
 
Joined
Jul 9, 2021
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That was my suspicion as well so I dropped the lower last night and ensured engagement when reinstalling. Prop appears to engage and lock out but it looks like I may need some cable adjusting. Going to muff and run today to confirm and report back.
Alright. So upon starting the prop does not spin and the engine cuts out which I thought was due to the cut off switch on the shift assembly, but the same thing occurs with that removed. I'm at a loss. It appears it isn't in gear and shifting causes stalls. I don't know how many more times I can remove the lower and retain my sanity.
 
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Jul 9, 2021
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There is no locking or clicking on the prop engagement either.
So my thought is the upper drive assembly is shot because the previous owner was running this thing without gear oil in the motor since they never replaced the quad ring and let it all leak out. What size sockets are the top bolts so I can remove and check? Worth pulling whole drive?
 

Bondo

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So my thought is the upper drive assembly is shot because the previous owner was running this thing without gear oil in the motor since they never replaced the quad ring and let it all leak out. What size sockets are the top bolts so I can remove and check? Worth pulling whole drive?
Ayuh,..... I'd pull the whole drive, it's easier to work on then,....

If yer top cap bolts are 12-point, it's 3/8" or 7/16" 12-point socket,....
 
Joined
Jul 9, 2021
Messages
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Ayuh,..... I'd pull the whole drive, it's easier to work on then,....

If yer top cap bolts are 12-point, it's 3/8" or 7/16" 12-point socket,....
Have the whole thing pulled. Trying to get the shift arm to engage gear and still no lock out...do you think the shift crank or spool assembly could be the issue?
 
Joined
Jul 9, 2021
Messages
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Have the whole thing pulled. Trying to get the shift arm to engage gear and still no lock out...do you think the shift crank or spool assembly could be the issue?
Update. Seems that the clutch engages when the lower unit is laid down. Hoping to keep engaged during reassembly and test tomorrow.
 
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