changing shift cabler in 1981 OMC 400 stringer

CptTrevor

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Mar 29, 2011
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Can anyone offer any advice? I need to know if it can be done without the special tool mention in the manual if not where can I purchase the tool? I am about to change the shift cable in my outdrive. I have the drive just sitting on the quadrant and still connected from inside by the shift cable. I just need a little technical advise on the correct manner to proceed. I have the original manual. I am a mechanic on cars not too familiar with boats but willing to learn with some good guidance. I just replace the tilt motor, the tru course steering cable, bilge pumps etc. I went to the marine store and ask for the lube and grease for the Upper and lower gear case and was given SAE90 and the manual state not to use SAE90 but the gentleman in the store say as long as it is not an electric shift it is ok to use can any one confirm. Cpttrevor
 

F14CRAZY

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Aug 12, 2008
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Re: changing shift cabler in 1981 OMC 400 stringer

Regular gear oil is fine as long as you don't have an electric shift.

I replaced my able last year so my memory i alittle rusty but I'm pretty sure you do need the special tool to pull the pulley shaft. The manual gives the part number and just ask your Evinrude dealer. I found it cheaper from a dealer online but it came in a new BRP package.
 

Howard Sterndrive

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Re: changing shift cabler in 1981 OMC 400 stringer

should use 80W90. 90 is a bit too heavy for most climates.

why are you changing the shift cable? More important... where did you find one, and are you sure you have the correct replacement?

Instructions for cable removal depend on whether it is being saved or it is scrap
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

should use 80W90. 90 is a bit too heavy for most climates.

why are you changing the shift cable? More important... where did you find one, and are you sure you have the correct replacement?

Instructions for cable removal depend on whether it is being saved or it is scrap

Howard the insulation on a small part of the cable covering in the outdrive is broken and the cable is fine but I feel that water can get in and damage the cable. I have located the cable at Marine Parts Source cost 488.00. I also spoke to another gentleman at Goreskilanding a place I was directed to by GLM and he told me if the cable is not frozen or damage just buy some heat shrink with adhesive and repair the damage spot he said it is done all the time. He told me I have to remove the outdrive which is partially done and the Uppergear case to fix the cable. If I can't fix it then I am going to order the cable and attempt to to the job that is why I am looking for information to be prepared for the worst situation. I have a hydro mechanical system I was told by the same gentleman after I gave him the serial number and model numbers of the outdrive. I just change the lube and replace it with SAE 90 I am in Florida. I am about to put some 4cyl motor oil in the clutch housing is that ok? Cpttrevor
 

Howard Sterndrive

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Re: changing shift cabler in 1981 OMC 400 stringer

you're in FL and you're calling Goreski's?

To remove cable:
1. Take battery out of boat.
2. remove cables and lever at converter housing behind the engine
3. take the 4 screws and cover off the converter
4. Remove the little cable end retainer clip and lift the plastic guide and unwind the cable from it
5. reach under the converter box where the cable goes in and pull the spring loaded cable tensioning pawls back while you slide the cable out
6. remove the cable retaining clip beside the ball gear on the back of the intermediate
7. pull the cable gently - helps if someone else pushes it - a person steadying the drive helps too
8. pull the cable out of the intermediate hsg
9. support the drive - remove exh hsg cover bolts
10 lift off top exh hsg cover and then lift out the upper while you work the cable through the hole in the upper carefully
11. set upper aside, and then you can decide whether you need to remove the exhaust hsg to access the cable
12. remove the exh hsg from the lower unit

then you'll have the lower by itself with the cable and can probably attempt your repair.
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

Howard thank you very much I am going to follow your instructions today after I am finished with the VA. Do you know where I can purchased that special tool to remove the cable just in case I have to go that far? Cpttrevor
Howard I have located the cable tool at JMS Marine Supply online PN#915271 cost 57.58. Again thank you for your help Cpttrevor
 

oldsub86

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Re: changing shift cabler in 1981 OMC 400 stringer

So, what does this "special tool" look like and what is it supposed to do?

Randy
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

If you go on JMS Marine Supply online there is a picture of tool it removes the shift cable part# 915271.Cpttrevor
 

Howard Sterndrive

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Re: changing shift cabler in 1981 OMC 400 stringer

that tool is for Cobra drives, not stringers... whatever manual referred you to that tool is not for your drive
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

thank you so where can I buy the tool or do you know the part number.By the way just for information where is Goreski located? Cpttrevor
 

Howard Sterndrive

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Re: changing shift cabler in 1981 OMC 400 stringer

I'm not sure what tool you're looking for. Goreski's marina is on Lake Scugog in central Ontario.
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

Howard when I first started to work on this boat I started to ask questions of people who are either boat mechanics or have some experience working on OMC boats. I spoke to a boat mechanic who is located in California and he called me numerous times about the tru course steering cable and help me take it out and identify the length. I told him about my Shift cable and he told me I need a special tool. After I read your comments last night I went to the manual and I can't find any reference to a special tool to remove said cable. Have you ever change the cable and do I need any special tools. I am mechanically inclined and have all the tools to work on any car with. If there is anything I need to remove this cable in the event I have to, could you tell me ? I am learning about boats as I go along. I made a stand to rest the outdrive on just have to release cable from inside but rain and lightning preventing further work right now. Any words of advice appreciated Cpttrevor
 

Howard Sterndrive

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Re: changing shift cabler in 1981 OMC 400 stringer

I have never needed a special tool to change the cable..... a seal pick and small fingers would help with the pin that attaches the cable converter to the "rack" in the lower unit.
If looking at used cables, look for one that still has the mechanism attached at the lower unit end.
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

Well my friend I am going to have to go on a diet and shrink my fingers or import some one with small fingers to help me out. I assume with the mechanism still attached at the end makes it much easier to reinstall for a novice like myself. It seems like you have plenty of experience with OMC boats. I appreciate your patience and help. This reminds me of when I went to my first command and my first Sgt told me to watch, listen and learn and this would help in being a knowledgeable Officer in the future. I hope it is not asking too much of your help I just went on Google and type in used shift cables for OMC 400 Stringer and on the fourth article from the bottom of the page is a listing on Ebay for a complete cable assy with housing attach could you tell me if that is the correct set up for my 400 stringer before I purchased the item thank you. I would wait on your reply.Item sold I have to learn how to identify parts for this boat. Cpttrevor
 

ybcoach

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Re: changing shift cabler in 1981 OMC 400 stringer

maybe you need the tool to retract the shaft out of the shifter housing . If you want to replace the cable, it might be usefull to get the pulley out of the housing. So , to do that: remove the four screws that hold the small cover on the shifter housing. Remove the cover and you'll see the two pulleys where the cables run on. The pulley that moves the pinion is the one to be removed. So you have to pull out the shaft that drives pinion and pulley. To remove it, take the plug out of the shifter housing, inside there, you'll see the top of the shaft
. it is threaded. Now you have to thread the "special tool" on the shaft and pull it out of the housing. Be shure to have all the seals ready to replace because they will be destroyed. You can make this tool yourself. Just a bolt that will go into the hole . Drill a hole in the top of the bolt.thread the drilled hole (i dont remember the thread size) Now run a nut on the bolt and thread the bolt on the shaft untill it's loked down. Now with the large nut , you use the bolt as a puller to remove the shaft . good luck with it.
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

thank you for the information. I removed the outdrive and pull the cable out the numbers on the cable are barely legible. I think the first numbers are 00 and I am not sure if the other part is rr then I am sure it is 001394 can you help me identify or where could I look to tell what type of cable this is and the length. Cpttrevor
 

ybcoach

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Re: changing shift cabler in 1981 OMC 400 stringer

the correct number is 981394 .The length is standard for those drives. The cables are fitted with melted-on extensions that fit the holes in the intermediate housing, the exhaust housing and shift assembly housing. BTw, repairing those cables is possible if the plastic isolation is cracked. Here in Belgium, we have these heat-shrinking tubes with a kind of glue on the inside. The tube shrinks and the glue melts his way into cracks . At the same time it seals perfectly and keeps water out. The shifter cable can be in perfect condition, even after 30 years. I sprayed teflon grease inside the cable tubes to keep the steel cables moving as smooth as possible.
Now , if you have removed the outdrive, the time has come to dismantle the whole drive. First remove the top cover, then you can lift the uppergearcase of the lower. It can be a little bit difficult to do it alone, so call-in some helping hands. Once the upper gearcase is removed, you can take off the exhaust cover by removing the 2 bolts on the outer rims of the lower gearcase. There is another one at the bottom of the tail, and one hidden under the rudder plate. Once those bolts are out , you can lift the exhaustcover . It will be "glued" on the swivel bearing retainer with silicone rubber, so it can be sticky. Take care about the shift cable that runs trough the opening in the cover. Once the cover removed, you'll see the shift housing with the shift cable attached to it. It is bolted onto the lower gearcase. remove those bolts and tap slightly sidewards with a rubber hammer to break the seal. When its loose, pull one of the shifter cables to lift the whole housing from the rack. Now you have your cable-shifter housing combination to work on . Succces!!
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

I thank you very much can you tell me if this is a mechanical shift or a hydromechanical shift is there a way of differentiating the difference through the cable? I am having a difficult time removing the four screws on the top of the exhaust housing and I would like to know can I use heat. I am not a boat mechanic but a car mechanic so I am learning as I go along and appreciate all of your help with this project. I am not afraid to tackle anything I love challenges. Just need some help in the right direction. Let me see if I understand you correctly. Once I remove the exhaust cover I can just lift the upper gearcase right out. Now where is the cable connected? I see where the cable is connected. I removed the upper but I had a slight problem the four bolts that holds the cover on were the hardest bolts I have ever moved. Two broke off and two came out. I have to use extreme heat now on the broken studs to remove them that is no problem they broke very high up near the heads of the bolts. I now have to get to the cable and if I understand you correctly I must removed the bolts in the bottom of the lower on the underside of the unit. I am trying to get a cable with the housing attached. I have to replace all the seals now. I am going to clean it up. Do I have to adjust anything? Cpttrevor
 

Howard Sterndrive

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Re: changing shift cabler in 1981 OMC 400 stringer

if this is a mechanical shift or a hydromechanical shift
hydro lowers have no anode behind the idle relief holes
400800lowerunitID.jpg
 

CptTrevor

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Re: changing shift cabler in 1981 OMC 400 stringer

Thank you very much I check and I have no anode behind the six holes. I now know I have a hydromechanical shift. I took the entire drive off and the upper gearcase off. I am about to remove the lower and go after the cable and housing. The cable is beyond repair. I have to replace. I am trying to locate housing and cable together. Got the broken studs out now I am about to drop the lower and see about getting the cable out. Are there any special paint to repaint the outdrive with and can I use stripper to remove the old paint ?My outdrive is presently white.I have remove the exhaust housing and those bolts -everyone of them I had to use the torch especially the one under the rudder the big bolt it took about two hours to move that bolt. I am now ready to get and install a new cable plus many new seals. Again thank both of you for the very precise information and directions. Cpttrevor
 
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