brynfrlin
16.05.2021 11:14:28
Re: 1990 alpha 1 mercruiser shift cable thread/tap size more
See full version: 1990 alpha 1 mercruiser shift cable thread/tap size
Re: 1990 alpha 1 mercruiser shift cable thread/tap size more
yes, I fought a good battle so far. The cable was cut. The 9/16ths stripped the nut. Tried a long chisel on an angle, no go. Tried left hand drill bits. Nope. Got to where the old cable is drilled out to where I can see threads. I'm hoping I can run a tap through to clean up the threads. more
Eric, that's a great tip. Mainly the tapping toward the center to move the stuck part away from the threads of the part you are trying to avoid damaging. Love it! [links]
Did you have issues removing the cable and now trying to fix the bellhousing?? more
As part of a bellows job, I'm replacing my lower shift cable. Unfortunately, I was following the manual and it makes no reference to leaving behind the shift cable core or some other sort of line to serve as a fishing line to pull thru the new shift cable. So, I've been struggling with getting the shift cable through the transom and into the engine compartment. more
After lots of contortions, I've got the cable thru the transom and under the starboard Y-pipe. I'm not sure the routing is correct, though. the manual (see below)shows the shift cable going UNDER the starboard motor mount, but in my case, it's going up and over the mount. In fact, I can't see how it would fit below the mount. the engine/coupler would be in the way. more
I'm trying to figure out if my routing is OK, but I can't find pictures, etc. online that clearly show the shift cable routing with the engine installed. As is, the cable doesn't seem to be making any sharp bends, but I'm concerned that it comes out of the transom plate and bends up, instead of of coming straight thru as the manual diagram seems to show. [links]
Re: Shift cable bellows-Alpha 1 Gen 2
Re: Shift cable bellows-Alpha 1 Gen 2 [links]
No, that is the process.
Nobody ever said boat repair was easy.
You can now do a static shift test.
Place the control in forward. The prop should lock in one direction and ratchet in the other.
Take a notice of the ratchet tension.
Now go into neutral. The prop should turn both ways free and no noise should be heard.
Place the control in forward gear.
The drive (and it's shift shafts) MUST be in forward gear to remove the drive.
Note: A counter-rotation drive (left hand turning prop) must be in reverse.
Remove the trim cylinders and let them hang.
Remove the six nuts that hold the drive to the bellhousing.
Lift the drive a little and let it drop to break it free and assist in removing it.
Careful! The drive is heavy and you might screw up your back!
Now, I made that sound simple but in many cases the drive can be stuck on.
Lifting the drive higher and dropping it a little harder each time might help.
If it's really stuck, then a series of chisels carefully and gently wedged between the drive and the bellhousing might help.
Sometimes removing a drive is just like work!
Now. keep your drunk friend in the boat. Just keep him happy with another beer or something.
Recheck to make sure you put thread sealer on the cable threads.
Have your friend gently pull on the cable while you use your new special 9/16" socket to thread the cable in.
Don't thread the cable all the way!
Leave one thread showing. here
Ya' know where that little stainless shaft pulled through? Well, if you look, you SHOULD see
a small shift shaft seal pressed up in the bellhousing.
This seal could leak water into the shift cable cavity and in most cases this is the reason
that your cable failed.
ALWAYS replace the shift shaft seal!
Mercruiser changed the seal to a brass barrel shaped bushing which press fits up into the bellhousing
and hangs down in the exhaust passage. It's about the diameter of a quarter and hangs down about one inch.
IF you have the cheesy old style little shift shaft seal, then pop it out and knock out the upper brass bushing as well.
Go to your Mercruiser Dealer and get the new style, dual lipped, brass shift shaft bushing assembly.
When you press the new bushing into place, make sure you sealed it with loc-tight! more
Before we start. This can be difficult and sometimes next to impossible to do if you have no experience.
The service manuals are vague and having a good friend with the right tools to help would be great.
This will cause serious damage.