Broken Control Box

mrkris

mrkris

Cadet
Joined
Apr 14, 2010
Messages
22
I was out this weekend with my 1977 Merc 500. I went for full forward a bit too hard and the damn thing popped and rotated all the way to 7 o'clock. I'm pretty sure its broken.

I've never messed with the control box so I have no idea how hard it is to fix. Do I buy a new / different one? Any advice before I get out my toolbox and start tearing it apart for the autopsy.

Thanks!
 
M

MacDaddy21

Petty Officer 1st Class
Joined
Feb 16, 2011
Messages
280
Re: Broken Control Box

I have a 1979 merc 40 with the Mercontrol control box with 2 levers (gear/throttle lever, and warm-up lever). I pulled mine apart and cleaned everything thoroughly and put it back together with no issues. Honestly, they are really not very difficult at all. I've seen the cams and most replacement parts on ebay for pretty cheap. From what it sounds like, the teeth on the shifter arm may have just stripped from where they mate in the box, but thats just a guess. You could buy a new one, but you'd be looking at 100 plus for one in good condition. Most of the ones I have seen are around that price. I say tear into it and figure out how it works. I like to know how all my stuff works, but thats just me. Also, i've had EXCELLENT luck with the members on this forum. They can walk you through just about anything, and I started out with ZERO outboard experience, and was able to completely repair my 40 to near perfect running condition. Good luck to you!
 
mrkris

mrkris

Cadet
Joined
Apr 14, 2010
Messages
22
Re: Broken Control Box

I'll open it up this week and post some photos of the guts.
 
hotrod53

hotrod53

Chief Petty Officer
Joined
Oct 16, 2009
Messages
508
Re: Broken Control Box

I have an electronic manual and it has that control box in it in section #8. It gives item numbers but not exact part numbers. The manual is 397mb in .pdf format, I'll gladly send it to you if it will help. I'm not sure how I can post it in this message, it says it's too large.

They are calling that part a "throttle lever".
 
C

carholme

Rear Admiral
Joined
Sep 4, 2010
Messages
4,845
Re: Broken Control Box

Here is a parts breakdown of the box:

http://www.crowleymarine.com/mercury-outboard/parts/640_28.cfm

Here is the Merc Controls Newest Manual which you can download to your computer:

http://www.4shared.com/document/Gsz8M-KN/Merc_Controls_Newest_manual.html

The first box in the file should be yours.

Here is one on ebay. Check the p/n on your broken one to make sure they are the same.

http://www.ebay.com.au/itm/New-Cont...at_Parts_Accessories_Gear&hash=item415b3a18f2

Gerry
 
mrkris

mrkris

Cadet
Joined
Apr 14, 2010
Messages
22
Re: Broken Control Box

Its the throttle lever. Part number 34671. The part is no longer stocked by the dealers in the area.
 
ajgraz

ajgraz

Lieutenant Commander
Joined
Mar 1, 2010
Messages
1,858
Re: Broken Control Box

Wow, you broke the more expensive of the two levers, the one that controls the throttle. Usually the other one (controlling the shift) goes first.

carholme said:
http://cgi.ebay.ca/MERCURY-QUICKSILVER-CONTROL-BOX-CAM-LEVER-34671-OEM-NEW-/390036346160

Gerry
Click to expand...

^^^This is a good deal for that part, plus it appears to come with a new roller.
(Note that carholme's link to ebay.au a few posts back is NOT the correct lever)

To the OP, make sure you save the old roller (in case your new lever does not have it), the little metal cam stop, and any other little parts that fell off; I can see them laying in the box in your first pic.

Also, carefully inspect the tracks inside the cam (part 22, p/n 59369) shown in carholme's link to crowleymarine diagram. The roller on the throttle lever rides inside these, make sure the track did not get nicked up.
 
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