Mercruiser Alpha Shifting Problem

[seecaptain]

I installed a new, complete aftermarket outdrive. The shift cable is new and it slides freely when the outdrive is off and after it is attached but not bolted on all the way. <br /><br />The problem happens when I fully tighten the six nuts that hold the outdrive on to the bell housing. When I tighten them up all the way the shift assembly freezes. If I loosen them up again and back the drive off a 16th of an inch everything moves freely again. <br /><br />Has anyone had this type of experience and/or have any suggestions on what the problem is and how I can fix it? <br /><br />Thank you.

 

[Don S]

Re: Mercruiser Alpha Shifting Problem

If the drive is an older Alpha, and not a Gen II, and the drive was trying to be removed without being in forware, either the upper or lower shift shafts (#21 and 22 below) could be bent causing the problem.<br /><br />

 

[qystan]

Re: Mercruiser Alpha Shifting Problem

Look at the mating of items 21 and 22 in the diagram above. <br /><br />Is the lever engaged in the shoe?<br /><br />If it is not, the throttle box lever must be in full forward position (not throttle only position) to set the shoe in the fore-aft position. The drive must be set in forward gear position for the lever to be in the same alignment.

 

[seecaptain]

Re: Mercruiser Alpha Shifting Problem

Should the vertical shafts of parts 21 and 22 be in a perfect straight line with each other when the outdrive is fully bolted on? It looks like the shafts align one on top the other only when I back the outdrive off an eighth to a quarter of an inch. <br /><br />I took off the upper shift shaft when I replaced the upper shift shaft bushings and inspected it. It appears to be fine. Is it possible for the intermediate shift lever (lower) to bend during an installation?

 

[Don S]

Re: Mercruiser Alpha Shifting Problem

Yes it could bend, if you didn't have it in forward. Or possibly you didn't have it in forward when you took it off?????<br />What year and model is your drive?

 

[qystan]

Re: Mercruiser Alpha Shifting Problem

Hopefully nothing is bent as Don described.<br /><br />Yes, both pieces must fit. Noticed that you mentioned that the cable is new. Changed it while replacing the drive?. If yes, its likely that the cable adjustment is too far off and there is no way you can get items 21 and 22 to align. <br /><br />Disconnect the lower cable at the plate. Mount up the drive, taking care to fit items 21 and 22. Use the straight fore-aft position to do this. You will need to turn the prop counter cw while turning the shift shaft to get the drive into the straight fore-aft postion and move the upper piece to fit this position.<br /><br />After its mounted, fit the cable and make adjustments.<br /><br />Good luck.

 

[seecaptain]

Re: Mercruiser Alpha Shifting Problem

It's an Alpha One. The outdrive is a new aftermarket outdrive manufactured by SEI (Model # SE106). I bought the boat used so I'm not totally sure about the age of the Bell Housing etc. The boat is a 1983 Searay Seville. The engine was replaced around 1997. <br /><br />I may have roughed up those parts you mentioned when I put the new outdrive on the first time. I've taken it off and on so many times trying to figure this problem out I can now do it with my eyes closed.<br /><br />I mounted the outdrive without the shift cable, shift slide, and upper shift lever to isolate the problem. So with only the upper shift shaft and the intermediate lever attached, I had the same binding problem when turning the shift shafts. So the problem is with parts 21 and 22.<br /><br />Everything moves freely until I tighten it up all the way. The problem seems to be in the upper and lower shift shafts as I pretty much ruled everything else out.<br /><br />I'm going to buy a new brass intermediate shift lever tomorrow and try that. I'll post my results after I put it together.<br /><br />In the meantime thanks for your suggestions and I think you put me on the right track with the possibility of a bent shaft. If you think of anything else please post it.<br /><br />Thanks again, <br />Frank

 

[djvan]

Re: Mercruiser Alpha Shifting Problem

Between the upper and lower housing on top of the shift shaft there should be a stainless steel washer, sometimes they are forgotten. Maybe in your case there are two of them causing an extra high part number 22. This is not likely but if you split the halves again it might be something to look at.<br /><br />DougV>

 

[FreeBeeTony]

Re: Mercruiser Alpha Shifting Problem

I don't know if this will make a difference.....is the drive shaft the correct length? I know that pre-Alpha and Alpha drives had different length shafts.

 

[J.J.W]

Re: Mercruiser Alpha Shifting Problem

Seecaptain,<br />If you would like, you can call tech support at Sterndrive Engineering<br />727-461-0811<br />or email at info@sterndrive.cc<br />Thanks,<br />Justin

 

[seecaptain]

Re: Mercruiser Alpha Shifting Problem

I want to thank everyone who responded to my post. But especially thanks Don S from Ketchikan, Alaska. He was right on with his suggestion that the brass intermediate shift lever was bent. I replaced it with a new one and all is finally well.<br /><br />Frank