Very hard to shift

[Smokey2074]

I've got an 87 Sunbird with a 140/3.0L Mercruiser IL4 with an Alpha 1 outdrive. My problem (well, one problem) is that it is very hard to shift from forward through neutral to reverse. This is key when returning to the dock, obviously. If it's in N, and I shift either to D or R, it goes smoothly - like when I just put it in the water, or if I have it in N idling in the water. But when it is in either gear, and I try to move from one to the other to maneuver at the launch, I have to work feverishly to get it to shift from one to the other. The control is brand new, but the problem was there in the old control. The transon oil is fresh and clean as well. Any thoughts?

 

[searay3]

Re: Very hard to shift

On top of the engine there is an assembly that the shift cables go to. Part if that assembly is a shift interrupt switch that temporarily cuts the ignition to allow you to get it out of gear. You'll need a manual to make sure all the adjustments are proper. If you give the serial numbers off your drive and engine some one will direct you to the right manual...

 

[Don S]

Re: Very hard to shift

Is it also stiff when you move from neutral to forward or neutral to reverse?
Or is it a problem of Very hard to get it out of gear, then it moves easily the rest of the time?
Two completely different problems and cures.

 

[Smokey2074]

Re: Very hard to shift

It isn't stiff at all going from N to either gear. The only time it is stiff is coming out of gear into N. Once it comes out of gear and settles into N, it is easy going into the other gear.

 

[Don S]

Re: Very hard to shift

Then you have a problem with your shift interrupt system. Either the shift interrupt switch is bad or the wiring going to it.
You can check this by operating the shift interrupt switch by hand with the engine idleing. The engine should die when you activate the switch.

 

[Smokey2074]

Re: Very hard to shift

Ok... I'll give it a try and let you know what happens.

 

[Smokey2074]

Re: Very hard to shift

Well, it would have been nice for that to have worked, but the switch seems to be working. With the engine running, and in N, when I activate the switch, the engine starts to die. It doesn't immediately die, if it's supposed to do that, but if I held the switch in, it would in a couple of seconds. Any other ideas?
Thanks so far!

 

[Smokey2074]

Re: Very hard to shift

Ok. I may have figured it out. When shifting into forward, the actuating lever assemby does not actually move and engage the switch. When going from N to R, it swings just fine and engages the switch, but not into or out of forward. Here is a picture of the cables, does it look like anything is missing from either cable?
Thanks!

 

[Smokey2074]

Re: Very hard to shift

I'll try the picture one more time

 

[Don S]

Re: Very hard to shift

When going from Neutral into either forward or reverse, the switch should NOT be activated. Only when coming out of gear when there is a load on the prop ( In the water)

 

[Smokey2074]

Re: Very hard to shift

Ok. Here's the sequences. When I put the lever into forward, the actuator doesn't move at all. As I pull back from forward into N, the actuator wiggles ever so slightly, but never rotates to the side to push the switch in. When I shift into R from N, the actuator rotates to the side, pushing in on the switch. As I move from R back to N, the actuator moves back to center, releasing the switch.
I haven't changed the cables at all, or messed with the switch. The boat runs fine in R, considering that the switch seems to be engaged.

 

[Don S]

Re: Very hard to shift

Your problem may be it's just never been adjusted properly.
Here's a link to Merc manual. Follow the steps starting on page 18.

http://www.boatfix.com/merc/Servmanl/6/6A2R3.PDF