'02 DF140 reverse issue

[BrokeAsMyBoat]

Recently I've been having problems getting my df140 into reverse. It would grind and that's it. I recently found out the shift shaft was damn near frozen and have lubed and worked it back to where it should be moving easily by hand. With the motor off I can put it in reverse and it feels "locked in" but when under power it still just grinds. Have I possibly rounded the reverse gear down to where it keeps jumping out under power? I've changed the lower unit oil and there was no trace of metal. Just wondering if there's any other things to try before tearing it apart. Thanks for any help!

 

[Silvertip]

Re: '02 DF140 reverse issue

If you've applied an abnormal amount of pressure on the shift lever you could have stretched the shift cable, damaged the control box, or simply moved the cable out of adjustment. But it does sound to me like you've rounded off the clutch dogs.

 

[BrokeAsMyBoat]

Re: '02 DF140 reverse issue

Any suggestions as to how to remove the drive shaft and prop shaft from the lower unit? I'm assuming the drive shaft has to move up in order to pull out the prop shaft, but are there any special tools or techniques?

I know the proper thing to do is buy a service manual, but I'm flat broke. The reason I'm doing this work is so I can sell the thing sitting in my yard I can't afford to put gas in. So if I was going to keep it I would buy a manual and not ask, but it's $80 I don't have to buy a one use item.

Thanks for any help!