Lower unit won't shift after Impeller change

[saltlydawg]

Hey Guys,

I have a 1990 Alpha one which I removed while I change the engine and decided to change the impeller at the same time. Today I reinstalled the drive unit with the shift lever in the fwd position and it went on east as can be, but now it will not shift.

I think I may have the shift lever arm and the lower unit cam alignment out of whack. Before I split the lower unit from the upper, I was wondering if I could get some sage advice from the forum.

Thank you in advance for the help!

 

[84EdH]

Re: Lower unit won't shift after Impeller change

You must have the prop locked in forward by turning it counter clockwise and holding it there with a bungee. This aligns the shoe of the lower shift lever with the slot of the intermediate. You can lie underneath the drive and look up to see if both pieces are facing straight ahead and engaged. Pull the drive back off and turn prop cc to align. Be sure end of shift cable in proper position also. Good luck!

 

[stonyloam]

Re: Lower unit won't shift after Impeller change

Need some info. Did you remove the whole outdrive or just the lower? Does the control move freely back and forth F to R or does it jam when you pull it back into R? There are only three things that can go wrong: you lost the washer under the intermediate shift shaft, the intermediate shift shaft went on "off a spline", or if you removed the entire drive the shift slide is disconnected from the upper shift shaft lever.

 

[saltlydawg]

Re: Lower unit won't shift after Impeller change

I removed the whole outdrive to split the case and I was doing a bellow change at the same time. It is jammed and will not go back from FWD, Back.

 

[ktbarrentine]

Re: Lower unit won't shift after Impeller change

Take the drive back off (the easiest and best way to get to the root of the problem and get it fixed "on-the-bench", and then do a proper pressure test). While doing that, check to make sure the shift roller on the upper shift shaft was properly engaged in the fork of the shift cable (the "block" on the end of the cable).

While the drive is off, move the shift shoe (on the intermediate shift shaft) fully CW (shoe facing straight fwd) and then see if prop locks CCW (sometimes helps to rotate prop CCW while turning the shift shaft CW to lock prop). The do the opposite... Rotate prop CW while turning the shift shaft CCW to the 10 o'clock position (REV) and see if prop locks while trying to turn CW. This tells you the shift haft is lined up right on the lower shift shaft splines. If you don't get the right response in this check, you need to split the drive and re-synchronize your shift shafts.

While the drive is off, move your shift lever all the way in REV, then back to FWD to see if it operates freely. Watch the shift cable end-block as you do that to see its action.

Now put it back on the boat. I find it easier if you use the nifty little plastic device to hold the shift cable block engaged in the roller while installing the drive.

When you get the drive bolted up , look underneath the bottom of the bell housing and see that your intermediate and upper shift shafts are engaged. If the intermediate shift shaft is not engaged, then you have a problem with the washer on the lower shift shaft bushing. Need to split the drive to fix that.

BTW...it is a "bellows" (yes, even just one....like a fireplace bellows...."bellow" is the sound you make when you find you have to replace it!).

 

[stonyloam]

Re: Lower unit won't shift after Impeller change

I removed the whole outdrive to split the case and I was doing a bellow change at the same time. It is jammed and will not go back from FWD, Back.

Got it! Should not have to remove the outdrive the problem is in the gearhousing (lower). When you put the gear housing on it was in reverse rather than forward, so the intermediate shift shaft went on "off a spline", so that when you pull back on the control the shift shaft tries to rotate CCW, but since it is already all the way CCW it will not go. So the fix: Make sure the control is forward, drop the lower, rotate the lower shift shaft (short splined shaft) all the way clockwise, turn the prop CCW till it locks and bungee in place. Make sure the top of the intermediate shift shaft is pointed straight ahead to match the bottom of the upper shift shaft, bolt er back together and you should be good to go.

 

[saltlydawg]

Re: Lower unit won't shift after Impeller change

Got it! Should not have to remove the outdrive the problem is in the gearhousing (lower). When you put the gear housing on it was in reverse rather than forward, so the intermediate shift shaft went on "off a spline", so that when you pull back on the control the shift shaft tries to rotate CCW, but since it is already all the way CCW it will not go. So the fix: Make sure the control is forward, drop the lower, rotate the lower shift shaft (short splined shaft) all the way clockwise, turn the prop CCW till it locks and bungee in place. Make sure the top of the intermediate shift shaft is pointed straight ahead to match the bottom of the upper shift shaft, bolt er back together and you should be good to go.

After reading everyone's comments and looking at the lower unit diagrams, I think you are dead right. It will take me a few days to get back to the boat, but I will write back to let you know if dropping the lower gear case and moving the shift shaft CW fixes my problem.

 

[saltlydawg]

Re: Lower unit won't shift after Impeller change

Got it! Should not have to remove the outdrive the problem is in the gearhousing (lower). When you put the gear housing on it was in reverse rather than forward, so the intermediate shift shaft went on "off a spline", so that when you pull back on the control the shift shaft tries to rotate CCW, but since it is already all the way CCW it will not go. So the fix: Make sure the control is forward, drop the lower, rotate the lower shift shaft (short splined shaft) all the way clockwise, turn the prop CCW till it locks and bungee in place. Make sure the top of the intermediate shift shaft is pointed straight ahead to match the bottom of the upper shift shaft, bolt er back together and you should be good to go.

Ok Guys I have resolution! I did exactly what is listed above and eureka, it shift like butter and went together easy as pie!
Thanks for the help and now onto the next project! :joyous: