1992 120 Force ............CATASTROPHIE!!!!!

[Mytox]

Interesting that there's another posting about a 120 HP Force shift rod. I had just changed the impeller and water pump in my 1992 120 Force, and my son was carrying the bottom end out to the boat to help me reinstall it, and he kind of slipped on the stair and ended up dropping the unit and bending the shift rod in the process. I think something got damaged internally when the rod got bent, and I'm going to have to somehow remove and straighten or replace the shift-rod and hope there's nothing else damaged. I seem to recall this is not a simple job, especially the connecting linkages etc, and I'm wondering if I should even be looking at it.

Egads.

 

[jerryjerry05]

There's nothing in there to bind or bend.
The rod goes through a seal and straight to the shift connector.
Maybe it's binding at the seal?
You might be able to remove it without disassembly.

Put it in an firm upright position.
Push the rod all the way down.
Fill with gear oil.
Slowly remove the rod.
Unscrew it at the seal too.
Straighten and reinstall.
You might get lucky and the rod goes back in without having to remove the plate.

 

[Mytox]

Thanks for the info and suggestion. I was able to remove the shift rod as per your instructions, straighten, and reposition it. I'm now trying to screw it back in to whatever it was I unscrewed it from, but can't seem to find the exact right spot. If I drained the oil perhaps I could see down the shaft to see what the target looks like at least?

 

[jerryjerry05]

The rod perfectly straight?
Maybe you can?
Probably not.
Sounds like you need to drain it and remove the cover.
When you reinstall don't over tighten.
Then do a pressure test.
I had a slow leak on one cover after replacing a seal and it took 3 hrs (of messing and sealer) to get it to stop leaking

 

[Mytox]

No Title

I'll take another shot at straightening the rod. It does still have a bit of a bend in it, so maybe that's it. I've searched the inter-web for a picture of the fitting it screws into and attached it (I believe it's #FA84621-1....although I could be wrong). Assuming this is the correct fitting, it appears it pivots on a pin or shaft and that may be the reason the threads on the rod won't engage (have to be perfectly lined up 90 degrees...maybe the slight bend is enough to throw it off?)??? I'll drain the oil and look down the shaft opening. To remove the seal to get a better view I guess I have to remove the cover plate and then the seal - hopefully so that it can be re-used? Dose it pull out fairly easily? Likely not is my guess. Hopefully i can resolve this by perfectly straightening the rod.

 

[Mytox]

No Title

It appears the photo won't attach. I'll try again.

 

[Mytox]

Here's my last try at the photo. I'll upload as an attachment.

 

[Mytox]

one LAST last time....

 

[Mytox]

I guess the picture never did make it onto the post.....thought I did everything right.

I drained the oil, removed the shaft, and shone a light down the 3/16" or so opening into the abyss. I could actually see the glint and basic shape of the fitting, but I'm going to have to remove the cover which I'll do tonight. I found some old instructions by Frank A for removing the cover from what I recall was 85 HP 1989 unit (?) and basically it sounds straight-forward (drain oil, remove water pump, remove cover....). I have a couple questions (and incidentally, I've ordered the Clymer manual for the motor, but it's taking a long time to get here): After removing the water pump and two screws holding down the bracket covering the shift shaft seal/opening, does the cover simply lift up off of the end of the drive shaft (with some persuasion with a putty knife or something to get things started as the cover is pretty glued down with black marine gasket goop)? Is there a drive-shaft seal that might get damaged and need replaced? Any tips??

The ice has blown out of the bay....sure be nice to get on the water before it freezes over again.

Thanks....rando