1. was it stalling when shifting into forward gear before you adjusted anything?
2. Cable play at 1/4" doesn't mean anything. There is NO spec for that.
Based on answer to number 1 will determine next steps.
Also how about some accurate history on boat and on shifting issues like when they started and if there were any over heating issues prior to shifting issue.
When was outdrive serviced last? Who did it, You or a professional?
DETAILS DETAILS....
Here are MY shift cable adjustments and measurements.
[FONT="]Trim outdrive up 1 inch of trim ram extensio from all the way down.
Take keys out of ignition!!!!!!!!!!!
Have a second person stand at the prop.
You, remove the short shift cable from the shift bracket. The one that goes to the outdrive.
After the cable has been removed, push the plastic cable end all the way in and hold in place while prop is being spun C’Clockwise..
Have second person rotate prop counter clock wise until the prop is fully engaged and wont turn anymore. Maintain light effort on shift cable plastic end pushing it to keep forward engaged.
Measure the distance from the center of the brass trunion/barrel to the center of the round mounting hole in the plastic end. Adjust trunion to make that distance 6 inches. no more no less!
Put shift control handle in forward FULL throttle position.
Remove the control shift cable (upper) from shift bracket at this time.
Install short shift cable back onto bracket at this time.
Take the shift control cable and adjust the trunion so it fits perfectly back into the shift bracket.
Before completely installing it turn the brass trunion 4 complete turns away from the plastic end and reinstall into shift bracket and install the nuts but do not tighten at this time.
Now put shift control handle in the neutral position.
Have second person spin prop, it should spin freely.
Put shift control into the forward detent position at ~ 10:00 position. NO FURTHER.
Have the second person rotate the prop counter clockwise. You should have solid engagement with no ability to continue to turn the prop.
Now shift back into neutral. Prop should spin freely with no clacking or clunking.
Now shift to reverse to the 2:00 o’clock detent position NO FURTHER!!
Have the second person spin the prop clockwise.
If you have positive engagement with no clunking or jumping out of engagement, you are done.
If it does not fully engage into reverse than look at the shift bracket where the short shift cable mounts and there is a slot. Loosen the 7/16 hex that is touching the bracket and move the stud so you are pulling the short cable. [/FONT]
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[FONT="]If this all works then tighten all nuts down making sure the cable ends move freely and the nuts are not tight against the shift cable ends. The studs must spin freely inside the cable ends.
Try this and retest in water under load.[/FONT]
[FONT="]If the stalling when shifting into forward or reverse still occurs then you may need a short shift cable replacement or the shift linkage in the bell housing has issues. Either way the outdrive will have to come off. The short shift cable should move very easily. If you feel a lot of resistance that typically means the cable is bad. The shift interrupter switch is activated when the short cable feels resistance when trying to come OUT of gear only under normal operation while running in the water. [/FONT]
[FONT="]So if the resistance is present when shifting into gear the interrupter switch will be activated and it should not be. Again this could be short cabkle or shift linkage at bell housing[/FONT]
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Anyway there are tests that would tell you if the cable is bad but to difficult to type out here but in general if you remove the shift control cable from the shift bracket, shift the control handle to full forward/wide open throttle and make a mark on the cable end, now go full reverse and repeat. Measure distance between marks, (2 7/8" to 3 1/8") anymore and replace the control cable.
Short cable measurement test,
Remove short cable from shift bracket, push all the way in and spin prop by hand C’clock wise until full forward is made. After it is in forward gear, with person holding prop in gear you pull very lightly until light resistance is felt, then make mark 1 on steel threaded tube at end of plastic connector.
Pull cable for reverse, spin prop clockwise, person holds prop.
Push cable very lightly until light resistance is felt the make mark 2 on threaded tube at end of plastic connector..
Measure between marks.
The measurement should be, if I remember correctly 1/2 " to 9/16". Anymore and the cable or linkage is bad.