DPS-B Chatter When Shifting to Forward

[ChrisS34]

I have a 2013 Volvo Penta 300. I am currently having an issue when shifting into Forward where the outdrive will "chatter"/"clunk" several times before engaging the gear. Reverse works fine. In testing, I have found that after first launching or after the boat sits for a while, the problem does not occur. After running the boat for a while, and stopping, then attempting to shift into forward, there will typically be this "chatter", assuming in the cone clutch.
I have replaced the shift cable, but the problem still persists. I just drained the gear oil (Volvo 75-90), and it seemed to have a little cloudiness to it, but still dark. I changed the gear oil, and tested it again, but the problem still occurred, but it took a longer run for it to occur. I checked the gear oil after the test run, and it looks good, so the water intrusion is not major, but I will address that as well.
I have heard that there are some adjustments that can be made with the Shift Assembly "dog", but the shift assembly on this unit does not have the bolt shims on the outside of the drive. I am hoping it is not the cone clutch, but I am running out of options. Any feedback/advice is appreciated.
Thanks.

 

[Scott Danforth]

If your shift linkage isn't adjusted correctly you can burnish the cone clutches

There is no "shift dog" on a cone clutch

Dog clutches are on outboards and Mercruiser Alpha drives

 

[ChrisS34]

If your shift linkage isn't adjusted correctly you can burnish the cone clutches

There is no "shift dog" on a cone clutch

Dog clutches are on outboards and Mercruiser Alpha drives

Thank you. I believe the linkage is adjusted correctly. It throws the shift assembly to the extents in each direction.
The "dog" I was referring to is on the shift assembly that engages the cone clutch to move it up and down for reverse or forward (not sure what that little mechanism is called). I have heard/read that this can wear and thus is not able to shift the cone far enough. Older outdrives have shims to adjust this motion, at least that is my understanding.

 

[Scott Danforth]

When your cone clutches wear, the shift fork isn't the part that wears.

The chattering is the cone slipping within the cup

Sometimes you can swap reverse and forward cones and reshim

However if the cone is burnished past the point where a bit of lapping compound helps, it's time to replace

 

[ChrisS34]

When your cone clutches wear, the shift fork isn't the part that wears.

The chattering is the cone slipping within the cup

Sometimes you can swap reverse and forward cones and reshim

However if the cone is burnished past the point where a bit of lapping compound helps, it's time to replace

Can you just replace the cone or is there a lot more to it? A shop I spoke with recently, said that if it is the cone clutch, that they would replace the whole gear stack in the upper unit. I also read that in new outdrives, that there is a coating that will get damaged if you lap the cups.

 

[Scott Danforth]

Rebuild info is in the factory manual