Re-assembled outdrive not shifting

[rich1295]

I have a 79 Mercruiser 226 HP - I believe a pre-alpha outdrive which I have replaced the lower unit and obviously did it wrong since when put back on the boat the throttle doesn't work - no neutral. I have removed the outdrive and the throttle moves and functions normally. Here are my questions:
1. When I re-assembled the outdrive it took 2 quarts of gear lube. When I took it off the boat I only retrieved 1 quart - is that normal? What happened to the other quart? I did turn the engine over a few times when it was assembled, but it wouldn't start.

2. What is the best method of assuring that the gears/shifting mechanism is in the right position when I re-assemble the upper and lower unit again?

3. I did not replace the water pump - is that a big deal. Anything special I should know if I try to replace that?

 

[stonyloam]

Re: Re-assembled outdrive not shifting

You are not the only one this spring. Only two possibilities:
If the control moves freely back and forth WOT forward to wot Reverse, you probably lost the washer that goes under the intermediate shift shaft and it has dropped down and not engaging the coupler on the bottom of the upper shift shaft.

If the control is jammed and you are stuck in gear the gearhousing was in reverse and not forward when you put it together and the i ss is off a spline. Fix: drop the lower rotate the lower ss (small splined shaft in front) all the way clockwise (forward gear) and rotate the prop CCW until it locks and hold tension with a bungee to keep it locked in forward. Make sure the control is in forward and the bottom of the upper shift shaft is pointed straight ahead. Bolt it back together making sure the i ss washer is in place and the top of the i ss is pointed straight ahead. You should be good to go.

If you did not remove the upper vent plug in the driveshaft housing the rest of the oil is probubly up there and will not come out because the hole is too small to allow air in. When you get it back together, remove both plugs and allow it all to drain then put it back in. I would not try to refill without first draining all of the oil.

It would be wise to replace the impeller. If this boat is new to you I would suggest replacing the pump housing too.

 

[ktbarrentine]

Re: Re-assembled outdrive not shifting

I have a 79 Mercruiser 226 HP - I believe a pre-alpha outdrive which I have replaced the lower unit and obviously did it wrong since when put back on the boat the throttle doesn't work - no neutral. I have removed the outdrive and the throttle moves and functions normally. Here are my questions:
1. When I re-assembled the outdrive it took 2 quarts of gear lube. When I took it off the boat I only retrieved 1 quart - is that normal? What happened to the other quart? I did turn the engine over a few times when it was assembled, but it wouldn't start.


2. What is the best method of assuring that the gears/shifting mechanism is in the right position when I re-assemble the upper and lower unit again?

3. I did not replace the water pump - is that a big deal. Anything special I should know if I try to replace that?

Just curious... You replaced the lower unit. Why? Was it new, rebuilt, or what? Do you have history on the impeller? If it is a used lower with no available history, then I definitely +1 recommend the pump work.
Also... Hmmm.. 2 qts of oil? until it came out the upper plug hole? sounds like a lot of "extra" oil to me. Wonder where it went?

 

[rich1295]

Re: Re-assembled outdrive not shifting

Yes, I did remove the upper vent plug, and when I filled it I pumped it until it came out of the upper vent hole. Still a mystery nowhere the extra oil went.
I actually bought a used complete outdrive and replaced my old one that had locked up when a propulse composite prop lost its fins and the motor overreved. I purchased a used outdrive that failed after about 30 minutes. Luckily on thhenoldmoutdrive it was the lower unit that locked up and on the used replacement it was the upper unit that failed. So I had the opportunity to put the two working units together.
I'm pretty sure I'm off a spline so I hope I can get that right on re-assembly. Thanks

 

[achris]

Re: Re-assembled outdrive not shifting

I have a 79 Mercruiser 226 HP - I believe a pre-alpha outdrive which I have replaced the lower unit and obviously ...

ARRRRRRRRRRRRRRRRRR ARRRRRRRRRRRRRRRRRRRR ARRRRRRRRRRRRRRRRRRR not a 'pre-Alpha'... No SUCH THING!!!!! Please, get the name of these drives right.... It's driving me batty...

It's really easy...

1967-1982 -> MC-1
1983-1984 -> R
1985 -> MR
1986-1991 -> Alpha One
1992- current -> Alpha One Gen II

Sorry for the rant... but Geez Louise :facepalm:!!!!....

Chris......

 

[rich1295]

Re: Re-assembled outdrive not shifting

Thanks, I have not seen that chart before - nice to know finally that it's a MC-1/
Good news is everything is back together and the shifting is fine.
Problem though is overheating. I did replace the pump housing, impeller and all gaskets. I matched the new impeller key so that it was seated in place. The impeller is a much tighter fit than I would have expected and I bent the fins in the same direction as the old one coming out, but there did seem to be a lot of friction and the impeller didn't move very easily when assembled. My muffs seem to be putting a lot of water out, but after a few minutes the temp gauge shows overheating running in forward gear at about 1000 rpm. Any suggestions as to what to try next?

 

[achris]

Re: Re-assembled outdrive not shifting

That sounds normal (difficult to get the impeller in the housing)... A simple test to see if the impeller is pumping is to watch how much water is flowing out from the muffs without the engine running, then have someone else start the engine while you watch. There should be a noticeable drop in the amount of water being lost around the edges of the muffs... If that is happening, then watch to see if you get water flowing out of the exhaust reliefs and/or the propeller hub.

Chris........

 

[rich1295]

Re: Re-assembled outdrive not shifting

I did the test and yes there was a considerable difference with the engine running - much less water lost around the muffs and there is water flowing out of the prop hub. I'm still concerned that it overheated when running for 15 min at 1000 RPM. Should I be? I suppose I'll have to get it in the water for a real test unless someone has any other ideas?

 

[achris]

Re: Re-assembled outdrive not shifting

I did the test and yes there was a considerable difference with the engine running - much less water lost around the muffs and there is water flowing out of the prop hub.

Good, that indicates the pump is pulling water up.

I'm still concerned that it overheated when running for 15 min at 1000 RPM. Should I be?

Yes.... You should be able to idle it all day on the muffs without an overheat...

I suppose I'll have to get it in the water for a real test unless someone has any other ideas?

It'll overheat just the same, only quicker.

Need to establish what engine you have (Merc never made a '226') and we can have a look at water flow diagrams and start a diagnostic path... Dealing with a similar problem on a Merc 260... That one's a bit of a nightmare..:facepalm:

Chris........
(Oh, and that's not an invitation to hijack the other thread... )

 

[rich1295]

Re: Re-assembled outdrive not shifting

Tested one more time with muffs. Idled at about 700 RPM after 10 min temp gauge reached middle of the red.
The engine is Mercruiser 228 serial no 5284523

If this was a car engine I'd say the thermostat was stuck closed.

Also, I've owned this boat for 8 years - never an overheating problem - just the outdrive issue that I recently resolved.

Rich

 

[achris]

Re: Re-assembled outdrive not shifting

...If this was a car engine I'd say the thermostat was stuck closed. ...

So pull the thermostat housing and test the thermostat....

Chris........

 

[ktbarrentine]

Re: Re-assembled outdrive not shifting

I betcha got some rubber chunks in there.... Think about a fwd flush and backflush after removing the thermostat cover and thermostat. Got a power steering oil cooler? might want to inspect anything in the water circuit.

 

[rich1295]

Re: Re-assembled outdrive not shifting

That sounds easy enough, if I knew where the thermostat housing was. - Sorry to be such a newbie.
Rich

 

[ktbarrentine]

Re: Re-assembled outdrive not shifting

Chris....time for the engine manual link.... "Engage!"
KB

 

[rich1295]

Re: Re-assembled outdrive not shifting

A manual would be a big help. The old impeller was in OK shape. No breakes or damage.
Rich

 

[rich1295]

Re: Re-assembled outdrive not shifting

Tried to remove what I think is the thermostat housing. (Large junction of hoses on the top front of the motor - has 47440 and 6 stamped on it) I removed the two 9/16th bolts and could not budge it. Also I was unsuccessful in removing any of the hoses from that part. Once the hose clamps were loosened the hoses still cling to the part and it seemed that I would break or damage the hoses if tried to peal them off. Any tips here would be appreciated. The hoses look to be in good condition, except that I can't remove them. I also started the engine again and observed that all the hoses connected to the thermostat housing (or what I assume is it) got hot with the exception of the very large one at the front and going down into the engine - It's 2" or more in diameter and remained cool while all of the other hoses 1 - 1/2 in diameter got hot. Muffs were connected and water flowing during this test.

 

[ktbarrentine]

Re: Re-assembled outdrive not shifting

Welcome to the wonderful world of working on aged equipment! I had the same issues working on my 5.0L 1990 vintage engine. Depending on how long those pieces have been mated will determine the amount of effort to remove them. They will come apart... just takes patience and time and lack of fear of breaking things, as long as it it done carefully... The cover is more than likely glued down with sealant, or just verry stubborn. Got mine off by gingerly using a flatblade screw driver to get into the joint and work it loose. Same for the hoses...small (narrow) screwdriver and taking my time finally got those to "pop" from their grip. If you are carefull enough, you can salvage the hoses. Otherwise, plan on replacing (what is their replacment history, anyway?). If your system is like mine, my T-stat was full of rust.... I flushed the system, dropped a new T-stat in, and everything was fine. (cleaned and tested my old t-stat and it was good, but as cheap as they are, it's in the dustbin.) HTH, good luck and let us knwo how it goes! --- Oh, and safety first! Be very carefull using screwdrivers, awls, etc while prying... one false move and you can gouge your hand! (experience talking). There are "special" tools for splitting gasketed parts.... Oh, and you will need new gaskets, of course.

 

[achris]

Re: Re-assembled outdrive not shifting

Chris....time for the engine manual link.... "Engage!"
KB

Huh... I guess that's all I am to some people, just a link to engine manuals....

Engine -> https://docs.google.com/open?id=0B1TAvwZ3Tjhfdk9PRXBWWExTU084dXpoTUhqRk9vZw
Drive -> https://docs.google.com/leaf?id=0B1...ODAxOS00YWZjLWFmZDgtZjMxNjQxOTkzMzUz&hl=en_GB

There you go... Have fun with your new 'best friends'....

Chris.........

 

[ktbarrentine]

Re: Re-assembled outdrive not shifting

Huh... I guess that's all I am to some people, just a link to engine manuals....

Chris.........

Hey now!! you're way more than that to me!! (us) When I grow up...I want to be just like you! (Well, actually, I just wish I knew half of what you have probably forgotten!! Maybe someday, if I pay close enough attention to these forums and do my homework!). And you're not only good for the manual links....your videos rock, too!

 

[rickryder]

Re: Re-assembled outdrive not shifting

You could try grabbing the hoses at the housing with channel lock pliers and twisting the to break them free.....gently please