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Discussion Starter · #1 ·
Guys,

I was out yesterday boat was runnimg fine. I came into the dock went into reverse on both drives, then back into forward. The port side drive lost forward gear. I checked the cables everything was moving as it should. I removed the cable from the linkage to the drive and I could manually shift it into neutral and reverse, but no forward. I pulled the boat out of the water and took the cover off the drive thinking it was something in the shift linkage, but everything was moving and working fine. I noticed that I can sometimes feel the prop catch when in forward, but if I rotate the prop backwards it will slip in forward. I guess what I am saying is that the prop will never catch or engage while in forward. What do you think this is? The gear oil was fine no metal and no water. I pulled the lower unit and have it with me. I left the boat at the cottage.

chevy 57
 

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Discussion Starter · #2 ·
I forgot to tell you that reverse works fine. With the motor running and boat in the water I manually shifted the cable to full forward and it would not move the prop. The catching I explained in my first post was done on land without the motor running.

chevy57
 

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My guess would be the linkage came disconnected or broke where the shift cable goes into the drive. Did you have your drive off for service lately? Your going to have to pull the drive to see if this is what happened. That happened to me one time.
 

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Take the back cover off. You will probably find some carnage in there. It happened to me. I had a set screw back out, and it ruined the entire drive as it traveled through it. Same exact symptoms.
 

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Discussion Starter · #5 ·
Guys,

I removed the back cover of the upper drive and everything was good. The linkage and bell crank are functioning and transferring motion. There is no metal or water in the gear oil.


chevy57
 

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I would guess the shift cable sheathing broke at one of the mount points. Look up under the drive where the black cable goes into the drive and make sure the outer part of the cable is not broken.
 

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The shift cable has worn a hole in itself where it goes past the coupler.
That is a pinch point and it is easy to get it rubbing the coupler. BTDT
 

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Discussion Starter · #8 ·
Guys,

I don't understand the shift cable theory, but I am going up after work today to pull the upper drive off and take a look. The drive goes into reverse which requires the linkage to pull the cable. If the cable was worn through or broke it would not be able to pull into reverse right?

chevy57
 

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You will be able to pull the cable but you can't push the cable because the outside casing is broken off the mounting point at the drive.
 

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Discussion Starter · #10 ·
OK. Now I understand what you are saying. When you move the shift lever it simply pushes the cable casing instead of the cable. I will check the cable end as it passes through the transom. I can see the linkage end is fine, but I did not check the other end. thanks.

chevy57
 

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I have a friend that had something similar and the surface on his cone clutch had become flatened out and would not engage. I guess this could happen from shifting at higher rpms over time or poor metal quality. But if you cant find anything wrong with the cable it might be something to look into.
 

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Discussion Starter · #12 ·
OK guys,

The cable was fine, so I pulled the drive. Everything was good with the linkage so I took the drive to a marina to pull it apart so we could look inside. No broken parts. The problem was exactly as 3wood described. The clutch was completely worn out. No taper left at all. The mechanic who took it apart could not believe it. He kept saying he has never seen one that flat. The problem for me is Merc. doesn't sell those parts anymore so I need to buy the upgrade kit that includes the cone clutch, gears and bearings about $1700.00 or try to find a used cone clutch.

chevy57
 

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I will ask him if the other half of his cone clutch was still good. I know he had to upgrade to the newer design, and I would have to believe the forward half of the clutch would be more apt to wear out. I will get back with you.
 

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O.K. heres the scoop, mercury doesn't make "that" cone clutch anymore. But the one they make now fits the newer bravo 1's Say 2005 or so will still fit the shaft on your drive, they don't tell you this so you will buy everything.
 
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