Upper Gear Shaft Washer Clearance, Hard shift forward and reverse

[krummel21]

Model: DPS-B 1.95

I am having an issue where when shifting into forward or reverse the boat shifts very hard. I talked with Volvo and they brought up checking the upper gear shaft washer to nut clearance (pictured). I was informed that I should have between .004" to .020" clearance between washer and nut (I marked the area measured). I was unable to get a .0015" shim in between these surfaces (the washer does spin). Am I measuring the correct spot?

Should I install a thinner washer?

The current washer number is 6, does anyone have the washer part numbers for the thinner ones?

Thanks in advance,
Krummel21

 

[HorizonblueDK]

Did you grab the nut with a pair of pliers and pulled upwards, when you measured? As far as I know, the shaft sinks down by gravity, it is not held in position by anything. But by pulling upwards, you should be able to see a gap and measure it.

 

[krummel21]

No I didn't, that makes sense though. I will do that and see what I find.

The next thing I was told to check was the shift cable. For diagnosing I have read to disconnect it, what to do after that I'm not sure on. Should I shift it manually at the prop with the engine off or on or neither?

Thanks

 

[HorizonblueDK]

When you say it shifts hard, I assume you mean that you hear a loud "CLUNK" when it engages, and not that you struggle hard with the controls to put it in gear. The clunk does not have anything to do with the gear cable or how it is adjusted, I would focus on the drive itself.

 

[krummel21]

Yes, exactly, it sounds harsh when shifting into forward or reverse.

I changed the oil and kept it at the half way mark, before it was about 3/4 up the flat area. This did not make anything better.

Going to try and pull up on the nut and see what I get for a measurement.