1996 Merc 115 Optimax - Shifting Problems

[roll_tide]

My shifter is extremely difficult to shift, especially into neutral or reverse. So much so that my wife couldn't take it out of forward. Later that evening when trailering I was trying to put in reverse/neutral and broke the plastic shifting lever Man I was PO'ed!!

I removed the shift and throttle cables from the engine and now the control shifts like butter, so I know it's not the control or the cables.

I tried shifting the linkage by hand with the engine at idle. I got it to go in forward by hooking the shift cable back up, and removed the cable while it was in forward. The shifting linkage will not budge. Not even with the control hooked up. Seems like it is basically not going into reverse at all. I can get it in neutral but it is a PITA!! What's the next step?

 

[Jeff_G]

Re: 1996 Merc 115 Optimax - Shifting Problems

Merc didn't make a 115 Opti in 96?

Pull the lower unit and see if the problem is there or in the linkage/shift shaft. If in the lower unit, take it to a good shop.

 

[roll_tide]

Re: 1996 Merc 115 Optimax - Shifting Problems

Sorryyyy it's a 2006 not a 1996!!!

But in order to pull the lower doesn't it need to be in reverse?

 

[roll_tide]

Re: 1996 Merc 115 Optimax - Shifting Problems

I removed the lower unit. How do I check to see if it is the lower unit that isn't shifting? Rotate the shaft counter clockwise until it "clicks" into neutral??

 

[roll_tide]

Re: 1996 Merc 115 Optimax - Shifting Problems

Well....I turned the shifter shaft on the lower unit and it clicks through the gears just fine.

I re-connected the shifting cable to the linkage at the engine to see how it the control lever felt while trying to shift with the lower unit removed. No different. It's obviously a problem with the shift shaft/linkage. How should I troubleshoot/correct this????

 

[Jeff_G]

Re: 1996 Merc 115 Optimax - Shifting Problems

Two things, one just follow the linkages and look for anything binding, just simple mechanical fix.
I put lower units up in neutral, but it doesn't make a difference which gear it is in as long as the shift linkage and control box are in the same. Be careful to align the water tube with the pump and the shift shafts.

 

[roll_tide]

Re: 1996 Merc 115 Optimax - Shifting Problems

Thanks Jeff.

It's dark already so I had to call it quits for today. I know one thing, that linkage is going to be a pain to get to. Looks like it's underneath the oil reservoir and powerhead but I know there has got to be something wrong with it there. The shifter won't move a bit when trying to shift the linkage by hand.

I will sleep on it and get a fresh look tomorrow. If I did have to have a shop repair it, what kind of price would I be looking at?

 

[roll_tide]

Re: 1996 Merc 115 Optimax - Shifting Problems

I have narrowed it down to either the shifter bushing or the cable.

After I reinstalled the lower unit and all the cables, it doesn't want to shift to neutral or reverse. I can get the control lever all the down to the reverse position but it stays in forward??

 

[Jeff_G]

Re: 1996 Merc 115 Optimax - Shifting Problems

Sorry not sure what you mean.
With the lower unit off and the control cables disconnected was the linkage still hard to move? Try to narrow it down before putting the lower back up. Sounds like something is binding. Make sure the shift shafts line up.

 

[roll_tide]

Re: 1996 Merc 115 Optimax - Shifting Problems

Yes, when it was disconnected, I could not move the shifter alond the slide with my hand. I decided to go ahead and put it all back together for now. I am active duty in the Marine Corps and just started leave yesterday. What a great way to spend time off of work! Since I only have 8 days of leave left to go, I figured I would just suck it up and deal with it for the time being and get some fishing in.

I can't see myself repairing it if the shift linkage or bushing needed to be changed. All the shops around here said it would be at least two weeks before they could even look at it.

After I got everything put back together, I noticed it was still hard to get into neutral to start the engine. I have to pull down on the control really hard to disengage the safety switch. Problem is after it starts the prop is spinning in forward. I pull the lever down to where reverse should be and it still is spinning in forward gear, doesn't seem like it will go into neutral or reverse.

At least before I took it apart to troubleshoot I could get it in reverse if I pulled down really really hard.

The previous owner says it was stiff from day one and the dealer told them that has it got broke in it would loosen up. They rarely used the boat, so I don't know if that bushing got corroded or what.

When I had the cable disconnected from the control and the shift slide, I could move it in and out with my hand but it wasn't near as smooth as the throttle cable. Is it possible to use the shift cable as the throttle and the throttle as the shift, just for troubleshooting purposes?