Trim out drive up 2 inches 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.
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 trunnion to the center of the round mounting hole in the plastic end. Adjust trunnion to make that distance 6 inches. No more no less! In cases where the shift cable is old but still works well you can adjust this dimension to 5 15/16”. NO MORE.
Put shift control handle in forward FULL throttle position.
Remove the control shift cable from shift bracket at this time.
Install short shift cable back onto bracket at this time.
My procedure that has worked for me for almost 30 years
Take the shift control cable and adjust the trunnion so it fits perfectly back into the shift bracket.
Before installing it, turn the brass trunnion 4 complete turns away from the plastic end and reinstall into shift bracket.
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 FUTHER.
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 position detent 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.
Try this and retest in water under load.
There are tests that would tell you if the cable is stretched/worn out.
Shift control cable measurement test.
If you remove the shift control cable from the shift bracket at engine, shift the control handle to full forward/wide open throttle and make a mark on the cable core where plastic end stops Now go full reverse and repeat making mark with black marker on core where plastic end stops. 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 CCW until full forward is made. Make a mark on shift cable core where the plastic stops over the metal.
Now with someone holding the prop to keep it from spinning pull the cable end out with two fingers, as soon as resistance is felt mark the inner cable where the plastic cable end ends. Now measure between the marks,
The measurement should be if I remember correctly 1/2 " to 9/16". Any greater than 9/16 then either the cable or linkage at gimbal housing or shift spool in lower unit is bad.
Remember, if the shift interrupter switch is not functioning no cable replacement or adjustment will allow the shift to get OUT of gear easily.
So to test interrupter switch simply start engine and depress switch and engine should stall. If not it is a bad switch or bad wire connections…