1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

saldri01

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Apr 24, 2011
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Howdy,

This is about a discovery I made on a 40352D I recently purchased as part of a nice package deal with a clean / beautiful 1963 Starcraft 14' runabout.

I replaced the water pump this past Friday. The parts list included the wear plate, impeller, housing, shaft seal, o-ring, screws (3), and gear lube for the splines on the driveshaft. Everything went very well. While I was at it I also replaced the thermostat, cleaned the intake screen, and flushed the cooling channels for proper flow. She moves water through the cooling channels nicely.

The next day (Saturday) I launched into a lake, engine purring, and found that I had no forward gear using the shift lever at the steering wheel. I went to the motor, disconnected the cable from the manual lever, and shifted by hand right at the motor. She goes into reverse and neutral easily. Engaging into reverse is solid, but I only grab forward gear a little and that's if I pull as hard as I can on the lever and hold it. It's a very weak engaging. As soon as I let up I've got no forward gear. So, since the wind had blown me halfway across the lake, I put her into reverse and headed back to the dock to load on the trailer and go home to research the problem.

My questions are:
What should I be looking for? Might it be a linkage adjustment, a clutch dog / worn gear issue, or something else entirely?
I've got the service manual, which explains (and includes pictures) how to replace the gears in the bottom half of the lower end so I know I can handle that with confidence, if that turns out to be necessary. However, the manual doesn't explain linkage adjustment. Is this something someone doesn't mind explaining or do any of you know of a good resource for detailed instructions?

I really apologize for this rather lengthy message and I appreciate everyone's time and input!
 

saldri01

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Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

Uh, oh! I just read two things in another post that have me concerned. No reasons were provided, but when uninstalling the water pump you're supposed to shift into forward gear and you're NOT supposed to remove the driveshaft from the lower end. (It would be nice if this was expressed in the manual!) Not knowing that, I did NOT shift into forward and I did remove the driveshaft. I'm not sure I believe this has led to my problem because if you rebuild the lower gearcase, apparently, the last thing you would do is install the driveshaft. Seems like if everything is in place... there wouldn't be any risks.

What are the repercussions of not shifting into forward gear for this procedure?
What are the repercussions of removing the driveshaft from the lower gearcase?
More importantly, at this point, what are the remedies?

Thank you!
~S
 

tx1961whaler

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May 31, 2008
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5,197
Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

What has probably happened is that the shifter coupling is not together correctly. Open up the access plate and see if it has slipped apart.
 

saldri01

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Apr 24, 2011
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Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

I'll check it in the morning to make sure, but I made sure the retaining screw went back into the groove on the lower shift rod like it was before disassembling.

I should mention that I don't know if it had forward gear before the work I performed because I hadn't ever had it in gear prior to launching it in the lake on Saturday. There may have already been a problem.
 

samo_ott

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Jun 18, 2006
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5,125
Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

You just answered my question as to the condition of the engine before you worked on it. Try the shift linkage and if not, then you will have to open up the LU. And welcome to the forum.
 

saldri01

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Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

Awesome link... thanks silver_bay!

~S
 

saldri01

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Apr 24, 2011
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Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

I'll try the linkage and move to the LU like you suggest, samo_ott. Thanks for welcoming me!

Update to come later.

~S
 

saldri01

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Apr 24, 2011
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Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

Sorry for the delay. I've got kids and they needed a swing set built. Pulled the trump card on me. That's okay, though.

Well, I think I got it and I have to say... WOW! If the shift rod was off a 16th of an inch I'd be surprised, but it appears that was the problem. According to the test at home, anyway. I'm trying to get my wife home from work with enough time to dunk it in the lake and give it a go. Let you know...

By the way, thanks for the input tx1961whaler, silver_bay, and samo_ott!

~S
 

saldri01

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Apr 24, 2011
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Re: 1963 Evinrude 40 hp Big Twin model 40352D - Foward Gear

Good to go, now. You guys were right and I was too sure of myself. Thanks for putting up with it.

She runs great and handles like a dream! Thanks, again!

~S
 
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