OMC Series 800 outdrive tilt not working

[csterner]

I have a 1979 twin engine Cobalt with the Series 800 outdrives. I have read several forums about this problem but none seem to answer my question. My tilt motor is spinning but not picking the outdrive up. I have taken the 3 bolts holding the outdrive "down" and removed them and then I strapped the outdrive up in the air out of the way. I took the cover off the clutch assembly, removed the clutch assembly, removed all the clutch plates, cleaned them, removed the worm gear(looks fine), cleaned the cavity really well, completly packed with grease. I also removed the lift motor from inside the boat and test ran it. It does spin. I checked the little copper spring loaded coupler and it has a few small nicks in it, but nothing too bad. The two little pins or teeth are still in it on either side. I cannot remove the shaft that the worm gear is on. I tried to pull it from the outside and it won't come out. When I looked in the shaft hole, all I can see is the shaft pin for the worm gear and a plastic bushing. There appears to be a copper something in there that is not letting me pull the whole shaft assembly out. I am assuming that shaft should pull right out. Is this correct? Am I even looking in the right area to fix this problem? please help!

Chris

 

[Howard Sterndrive]

Re: OMC Series 800 outdrive tilt not working

the shaft should slide right out. What happens is the 2 little roll pins that push through it crossways, break.

When they break, the little bits of hardened roll pin jam that shaft in there.
You have to get it out somehow.

 

[csterner]

Re: OMC Series 800 outdrive tilt not working

I will take a mallet to it tomorrow and see if I can bang it out of there. But is that brass looking thing supposed to come out as well? Also, if the motor spins and the shaft that connects to the motor spins and the roll pin is hooking up to the worm gear is ok, could the problem be before the worm gear in this shaft cavity?

Chris

 

[Howard Sterndrive]

Re: OMC Series 800 outdrive tilt not working

the brass part you see stays in there as I recall.

Also, if the motor spins and the shaft that connects to the motor spins and the roll pin is hooking up to the worm gear is ok, could the problem be before the worm gear in this shaft cavity?

If the motor spins and the shaft that connects to the motor spins and the roll pin is hooking up to the worm gear is ok your drive would be going up and down...

a new tilt shaft is $12 for a reason

It is a sacrificial part

When someone drops the drive at 300 miles an hour (which is easy to do!) it breaks.

 

[csterner]

Re: OMC Series 800 outdrive tilt not working

Wow! That was it(at least so far!) The slit end on the worm gear shaft that connects to the lift motor was sheared off. I couldn't see it from inside the engine compartment. Thanks for all the help!!!

 

[csterner]

Re: OMC Series 800 outdrive tilt not working

Ok, it turns out that I got more problems than just the tilt shaft. After fighting all day with 2 broken bolts, I was able to get the new shaft in place. I tried the tilt and all I got was a click this time. Sounds like the clutch was clicking. Maybe I did something wrong with the clutch plates. I separated them all(keeping them in order...hopefully!) and cleaned them really good. I then placed everything back in and packed it full of grease. Is that correct so far? The only question is the 3 outer large washers that are cupped. I tried to squeeze them down with a C Clamp but couldn't get it to squeeze far enough down. And even if I could squeeze it that far down, I can't get the ring on without removing my clamp! So I tried it the other way where the outer lip of the washers are away from the clutch plates and then the ring fit perfect. Is this the right way? Would this cause just a click with nothing turning? I did test the motor before replacing the broken tilt shaft and it was spinning before....

 

[superbenk]

Re: OMC Series 800 outdrive tilt not working

Try loosening the tilt housing cover a little bit & see if it works. I've doubled up the gasket on the tilt housing to allow enough play for the shaft not to bind.

If you still get clicking, check your battery charge. You want lots of juice to make it work or else it might just click.

If you still get clicking after charging your battery, you may have bad solenoids. You can try shorting them out to see if you get some action. If so, they're only about $12 each to replace (they can corrode or char internally reducing their conductivity & effectiveness). Also check all your electrical connections to make sure you don't have any corrosion or loose connections anywhere.

 

[wire2]

Re: OMC Series 800 outdrive tilt not working

... I can't get the ring on without removing my clamp! So I tried it the other way where the outer lip of the washers are away from the clutch plates and then the ring fit perfect. Is this the right way? ....

The cupped washers are the spring that gives you clutch friction, to operate the tilt. They have to face in to keep pressure on the plates.
If you have one facing out, it will not grab the shaft to turn the gear.
Check in the manual.

When I had mine apart, I made a jig to fit a bench vise. Then it was easy to compress the pack & put the ring on.