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Author Topic:   1998 Mercury Gear Case Shift Shaft

Don SSDD posted 07-01-2014 08:39 AM ET (US)
[From a 1998 Mercury outboard engine of unknown horsepower or model] I removed the lower unit and had a shop replace the seals, as it had a water leak in the gear case. When I got it back, the unit would not shift out of forward. The shift shaft coming out of the lower unit will turn about half a turn in either direction with little or no resistance and no change of gear. When I turn the prop clockwise it clicks and it won't turn counter clockwise.
The shift shaft on the lower unit will move up and down a little, but won't do anything different, other than move that half a turn. On the engine side, the shifter shaft only turns about one cog for each gear selection, so what I am seeing on the bottom end is not right.
Last evening I pulled the lower unit shift shaft with the retainer and o ring. I had not drained the gear oil yet, so I can't see where the shaft seats and I couldn't feel it fit back in place correctly. I will drain the gear oil so I can see.
Any advice? How does that bottom end seat? Is there something down there where it seats and is there something that should hold the shaft in place down there?
Thanks,
Don
jimh posted 07-01-2014 08:58 AM ET (US)
It sounds like the shop that worked on the gear case has goofed up the shift mechanism.
Don SSDD posted 07-01-2014 10:15 AM ET (US)
I drained it, looking down the hole, I don't see any solid looking female gears. I assume it is striped or I'd be seeing gears that would be obvious and would mesh with the male shaft.
Is there a key or something that holds the shaft down or is it the bracket up top held down with 2 bolts that fastens it down? I see some small very fine metal shavings on the drain plug, I'll check in the oil for more.
We are having weather in the 90's finally, would be great to be out on Mahone Bay in a boat.
Don
outragesteve posted 07-01-2014 02:59 PM ET (US)
What engine do you have? I'd be back at the shop who "repaired" the unit ASAP so you can get out on the water by the 4th! Good luck
Don SSDD posted 07-01-2014 04:17 PM ET (US)
I thought I gave a great description Jim........its a 90HP 2 stroke on a 1987 Montauk.
Thanks, Don
sosmerc posted 07-03-2014 01:39 AM ET (US)
Always best to post the engine serial number when discussing Mercs. Anyway, it sure sounds like the shift cam inside the gearcase is not installed properly AND/OR the pin at the front of the propshaft that rides on the cam was accidentally left out. The clutch is spring loaded towards forward gear, and from your description, the gearcase is stuck in forward gear.
The gearcase needs to come apart and be reassembled correctly.
Don SSDD posted 07-03-2014 04:47 AM ET (US)
Thanks sosmerc. Would that cam have been apart with a change of seals for the leaky lower end?
S/N 0G652002, 1998 90 ELPTO.
Thanks for all the help.
Don

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Author	Topic: 1998 Mercury Gear Case Shift Shaft
Don SSDD	posted 07-01-2014 08:39 AM ET (US) [From a 1998 Mercury outboard engine of unknown horsepower or model] I removed the lower unit and had a shop replace the seals, as it had a water leak in the gear case. When I got it back, the unit would not shift out of forward. The shift shaft coming out of the lower unit will turn about half a turn in either direction with little or no resistance and no change of gear. When I turn the prop clockwise it clicks and it won't turn counter clockwise. The shift shaft on the lower unit will move up and down a little, but won't do anything different, other than move that half a turn. On the engine side, the shifter shaft only turns about one cog for each gear selection, so what I am seeing on the bottom end is not right. Last evening I pulled the lower unit shift shaft with the retainer and o ring. I had not drained the gear oil yet, so I can't see where the shaft seats and I couldn't feel it fit back in place correctly. I will drain the gear oil so I can see. Any advice? How does that bottom end seat? Is there something down there where it seats and is there something that should hold the shaft in place down there? Thanks, Don
jimh	posted 07-01-2014 08:58 AM ET (US) It sounds like the shop that worked on the gear case has goofed up the shift mechanism.
Don SSDD	posted 07-01-2014 10:15 AM ET (US) I drained it, looking down the hole, I don't see any solid looking female gears. I assume it is striped or I'd be seeing gears that would be obvious and would mesh with the male shaft. Is there a key or something that holds the shaft down or is it the bracket up top held down with 2 bolts that fastens it down? I see some small very fine metal shavings on the drain plug, I'll check in the oil for more. We are having weather in the 90's finally, would be great to be out on Mahone Bay in a boat. Don
outragesteve	posted 07-01-2014 02:59 PM ET (US) What engine do you have? I'd be back at the shop who "repaired" the unit ASAP so you can get out on the water by the 4th! Good luck
Don SSDD	posted 07-01-2014 04:17 PM ET (US) I thought I gave a great description Jim........its a 90HP 2 stroke on a 1987 Montauk. Thanks, Don
sosmerc	posted 07-03-2014 01:39 AM ET (US) Always best to post the engine serial number when discussing Mercs. Anyway, it sure sounds like the shift cam inside the gearcase is not installed properly AND/OR the pin at the front of the propshaft that rides on the cam was accidentally left out. The clutch is spring loaded towards forward gear, and from your description, the gearcase is stuck in forward gear. The gearcase needs to come apart and be reassembled correctly.
Don SSDD	posted 07-03-2014 04:47 AM ET (US) Thanks sosmerc. Would that cam have been apart with a change of seals for the leaky lower end? S/N 0G652002, 1998 90 ELPTO. Thanks for all the help. Don