85 hp force shift coupling assembly reinstall

[jnm2645]

I have a 1989 85 hp force outboard with the 2 piece driveshaft. I can't find the serial number but the diagram ref. a 1989 85 hp ser. #ho858x89g seems to be accurate enough.
The problem I am having is I removed ,F498891 | PIN-SHIFT PIVOT, by accident and wound up rebuilding the lower unit. I didn't see how the shift coupling assembly came off and I keep having a problem when its reassembled. The shift coupling has 2 short forks and 2 long forks that should be attached to the lower shift linkage rod with the forks pointing down and to the rear. The diagrams all seem to indicate the short fork goes to the rear of the housing,which is the only way it seems to want to install correctly. Well when its all put back together if you pull up on the shift rod you hear a clunk and the shift yoke drops into the gear housing and apart it comes again. Yes I reinstalled the pivot pin. When disassembled if I try to rotate the coupling assembly 180 degrees the shift linkage rod won't line up to be connected. When the linkage is assembled with the fork pointing down it reverses the shifter. In the forward position the clutch goes onto the reverse gear and in the reverse position the clutch moves onto the forward gear. The Big question is does it sound like I'm installing something ,the fork, incorrectly. I purchased this engine on the boat recently and I've only run a few short times.If anyone can help it would be appreciateed, Jeff

 

[Frank Acampora]

Re: 85 hp force shift coupling assembly reinstall

The yoke installs on the pivot pin with the screw block rearward (toward prop) and the forked levers facing down and forward (bullet end). Thus when you push down on the shift rod, the yoke moves forward and pulls the shift shaft forward. This moves the dog clutch forward into the dogs on the forward gear.

Now: To install the drive shaft and brass saddle yoke, it is easiest to leave off the water pump and lower plate so you can look down into the lower unit. It is very easy to install incorrectly and the brass saddle will drop off when you try to activate the shift rod.

Use some heavy grease on the saddle and shift shaft. Hold the lower unit so the opening for the spool is UP. When you try to install the shaft, the dog clutch will drop into forward position by gravity. With only the prop shaft and dog clutch assembly, pass the shaft with the saddle through the forward gear. Make sure the saddle has not turned and is aligned with the forks. Pull up all the way on the shift rod or until the slots in the yoke align with the tabs on the brass saddle. As the saddle tabs enter the slots, push down slightly to seat it and let it move the yoke fully forward. Now, without pulling the drive shaft, turn the unit to its normal operating position and work the shift rod to ensure that the clutch will move both forward and backward without gravity. HOLD the prop shaft so it does not move out of the forward gear. If all is well, then turn the unit again and install the reverse gear, bearing carrier, and spool.

If it does not work, retrieve the saddle and try again. Yes, you need to be able to walk and chew gum at the same time to do this.

 

[timbramo]

Re: 85 hp force shift coupling assembly reinstall

The yoke installs on the pivot pin with the screw block rearward (toward prop) and the forked levers facing down and forward (bullet end). Thus when you push down on the shift rod, the yoke moves forward and pulls the shift shaft forward. This moves the dog clutch forward into the dogs on the forward gear.

Now: To install the drive shaft and brass saddle yoke, it is easiest to leave off the water pump and lower plate so you can look down into the lower unit. It is very easy to install incorrectly and the brass saddle will drop off when you try to activate the shift rod.

Use some heavy grease on the saddle and shift shaft. Hold the lower unit so the opening for the spool is UP. When you try to install the shaft, the dog clutch will drop into forward position by gravity. With only the prop shaft and dog clutch assembly, pass the shaft with the saddle through the forward gear. Make sure the saddle has not turned and is aligned with the forks. Pull up all the way on the shift rod or until the slots in the yoke align with the tabs on the brass saddle. As the saddle tabs enter the slots, push down slightly to seat it and let it move the yoke fully forward. Now, without pulling the drive shaft, turn the unit to its normal operating position and work the shift rod to ensure that the clutch will move both forward and backward without gravity. HOLD the prop shaft so it does not move out of the forward gear. If all is well, then turn the unit again and install the reverse gear, bearing carrier, and spool.

If it does not work, retrieve the saddle and try again. Yes, you need to be able to walk and chew gum at the same time to do this.

 

[jerryjerry05]

timbramo: you have a question or just want to share Franks wisdom and expertise ?? Jerry

 

[timbramo]

Hi Jerry, I am sorry, I did not finish my post. I just wanted to thank Frank for the information. I was able to get my lower unit back together fine after reading his post. I am not an experienced outboard mechanic and assumed this unit would be like most with the spring loaded clutch dog. Thanks again!

 

[jerryjerry05]

I'm pretty sure Frank would like the accolades. But Frank passed a few years ago He was one of the best and went way too early.
And thank You.