(MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

[cecho]

I have several questions on this subject.


The manual is not very clear on this. What's the best way to remove the shift shaft? I assume apply heat and hope the screw head doesn't strip is my best bet. How much heat should I apply? Should I try to remove it while hot or am I just trying to loosen it up?

=====================================
NOTE: It may be necessary to apply heat to shift
shaft lever screw to aid in removing.

1. Remove upper shift shaft lever and shift shaft.
=====================================


Once I get it off how do I =install the new bushings? The manual says:

=====================================
All units built after serial number 0D644650 will have the
following bushing installed. The seals were previously
installed into the bell housing upper bore. They now are
already installed in the bushing and can be installed with
one procedure using Bushing Tool 91-805057A2
=====================================

I can't seem to find the Mercruiser PN 91-805057A2. That seems to usually mean it's not a necessary tool or it's not a job I should attempt to do. The manual already assumes I have the new stuff installed. I don't think my drive does though.

It's an MC-1 898 with a Chevy 305. I'm using Manual #6 by recommendation though my drive's serial number is 5178761.

Thanks for any and all help!

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

My guess is after I get the shaft off I drill out the old holes enough to fit these puppies and hammer them in:

23-805041A2

 

[stonyloam]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

Here is your parts diagram: http://www.mercruiserparts.com/Show...0065.png&inbr=2203&bnbr=60&bdesc=BELL+HOUSING

You should be able to unscrew pin# 27, and then just remove the shift shaft lever and slide the shaft down and out. You should be able to use a brass drift and just drive the old bushings up and out (do not drill). Then just drive the new bushings in. The new bushing will be different, the fat end (with the seals) goes down. Here is a kit showing the (overpriced) driver Bell Housing Parts . IMHO it would be unwise to use anything other than OEM Mercruiser parts, aftermarket seals can be OK but they can also be crap, so I do not like to take a chance. Good luck.

 

[Eric 3.7LX Alpha 1]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

Do not drill them....

I was not easily able to unscrew Pin#27. I read online somewhere you can crack the arm #25 with a cold chisel and hammer and just pull it off. I tried heat, WD-40, PB Blaster, none worked... I think I used heat to remove the alled screw but ruined the roller in the shift arm with the heat... but that was mine. Was not a problem as I replaced both the arm and allen screw with the new bushings/seal.

I used threaded rod with a nuts and washers and pulled the bushings out and back on, it was very easy... think it was a section of 5/16" threaded rod and some 5/16" nuts. I had to hit the corners of the nuts on a bench grinder to round off the corners and do the job. The lever and allen screw are readily available and reasonably priced..... so don't worry about trying to save either.

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

That screw is firmly in place. I'm going to look into breaking the arm with a chisel.

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

I got it out with a tiny hacksaw and a small chisel. I cut the top of the shift shaft with the saw though. Is this OK to use after cleaning the sharp edges off or should I replace it?

 

[dubs283]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

I'm going to look into breaking the arm with a chisel.

couple of sharp whacks with a chisel will do it, no prob

just use a 1/4" drive extention and appropriate size socket, to remove the old bushings and to install the new ones

ive done the job using both the merc tool and sockets/extention

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

So I guess my best bet would be to get some 5/16" threaded rod, nuts and washers and use that as a tool to push out the old bushings and push in the new bushings? My alternative would be to use a 1/4" socket and extension and a hammer to tap the old ones out and old ones in?

I was thinking the top bushing was of a different size and would require a new hole.

 

[Eric 3.7LX Alpha 1]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

No. the new bushings use the same sized holes as the old ones. The aluminum on the drive doesn't get disturbed except for cleaning/ prep for the new parts.

 

[achris]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

It's an MC-1 898 with a Chevy 305. I'm using Manual #6 by recommendation though my drive's serial number starts with 571XXXX.

Not sure who told you to use manual #6, but that is the wrong manual. Your number (as incomplete as it is, and I have no idea why people do that ... Why not give us the full number???) indicates that you should be using manual #4....

Would you use the wrong manual for your car?

Chris........

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

Serial numbers are like ID numbers. I feel as odd about giving a full serial number as I do a social security number. I wish I could just us a model number instead. I wasn't aware the whole serial number was needed. Usually, just the first part is enough for almost everything else in the world. :lol:

The entire number is 5178761 (I had a temporary bout of dyslexia in my first post it seems).

I was told to use the newer manual because my drive probably has upgrades in it that make the old one obsolete. I also don't remember the last time I needed a manual for a car. I can do just about anything on one without a manual and when I do need one the information is generally readily available online... or on a spec sheet

 

[achris]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

Serial numbers are like ID numbers. I feel as odd about giving a full serial number as I do a social security number. I wish I could just us a model number instead.

No, I can't use a Mercruiser serial number to get unemployment benefits, or open a bank account. The only thing I can use your Mercruiser serial number for is to give you useful information about it.

I wasn't aware the whole serial number was needed. Usually, just the first part is enough for almost everything else in the world. :lol:

Well, now you are....

The entire number is 5178761 (I had a temporary bout of dyslexia in my first post it seems).

I was told to use the newer manual because my drive probably has upgrades in it that make the old one obsolete.

There are no 'upgrades' for Mercruiser drives. Sometimes parts are superseded, but the original manual is still the one you should be using. If new parts are required and they have a different set-up procedure than the manual states for the original parts, a leaflet will accompany the new parts.

Chris...

 

[bob johnson]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

well, i doubt many people are gearing up to come claim your motor, but you are wise, to not give out too much info, if it isnt needed.

if your motor was worth $6000 or more, some jerk, who needs a motor like that might concoct a story for the police that his motor was stolen and the serial # isXXXXXXX, and depending on how good the rest of his story is( usually bad, but you never know how once in a while someone is brilliant) good...then the police are left to wonder if you actually did "borrow" his motor

just saying.....the worlkd is full of rip off artists, who work twice as hard as a regular job to rip people off.... just look at craigslist

bob

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

well, i doubt many people are gearing up to come claim your motor, but you are wise, to not give out too much info, if it isnt needed.

if your motor was worth $6000 or more, some jerk, who needs a motor like that might concoct a story for the police that his motor was stolen and the serial # isXXXXXXX, and depending on how good the rest of his story is( usually bad, but you never know how once in a while someone is brilliant) good...then the police are left to wonder if you actually did "borrow" his motor

just saying.....the worlkd is full of rip off artists, who work twice as hard as a regular job to rip people off.... just look at craigslist

bob

That's exactly why I don't like doing it. I've read a few stories about VIN thieves. I'm not too worried about the serial number on an out drive that's about to crap out attached to a 35 year old boat and motor, but I still don't like the idea of giving out that kind of info online.

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

The bushings went out and right back in with a 5/16th-18 threaded rod, 2 nuts, 4 washers and a 3/8 x 1/2 x 5/8 x 1 bronze flange bearing. The total for the parts was $6... over $3 was for the flange bearing. I don't have a grinder for the nuts so I decided wasting $3 was a lot easier. lol

The new top bushing is ginormous!

When I took the lower shift cable out I also noticed it had grease down half its length. I'm going to assume that's a no-no.

 

[Cresco750]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

That's exactly why I don't like doing it. I've read a few stories about VIN thieves. I'm not too worried about the serial number on an out drive that's about to crap out attached to a 35 year old boat and motor, but I still don't like the idea of giving out that kind of info online.

Gee I wish someone would come and pinch my old drive! Do me a favor!

 

[cecho]

Re: (MC-1 Alpha 1) Removing shift shaft and replacing seals / bushings.

Sorry, I see you are in NZ, I don't think my boat'd make it that far.