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Evinrude 85hp stuck in forward

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Brettjod

New member
Hello. I have a 1976 Evinrude 85 hp outboard. Model# 85693g. When I was on the water a couple weeks ago my engine decided to get stuck in forward. I could not get it to shift into neutral or reverse. I unhooked the cables and the controls moved smoothly from forward to reverse. I have since dropped the lower leg. I can turn the prop both directions but turning in reverse is a bit harder. I have started to disassemble the lower leg to try and find my problem. I have it tore down so I can see the forward gear and was in the process of trying to get the shift assist cylinder out. According the Seloc manual I should be able to pop it out and the shaft at the same time. The push rod for the shifter moves up and down but a very small amount but I cant pull it out. Wondering if anyone has some tips for me or has any idea what might be my issue. I will include a couple pictures. Thanks in advance. 20200830_141012.jpg20200830_140951.jpg
 
Well---I have done the job more than a few times.----That is how it comes apart !!----Use the shift rod to grip the servo assembly ??
 
I've tried pulling on the assembly, I've tried using a big flat screwdriver to try and pop the shift rod out. Nothing. It moves up and down about 1/8" and thats it. Im not sure if its seized in there or what but it wont pop out.
 
Well I think I might have to talk to a boat mechanic and take it in. I've tried everything I could and anything I could fit in that small area to try and pop the assisit cylinder and shift rod out but it wont come out. It moves up and down a little bit but thats as far as it will move.
 
Exactly what is moving 1/8", the shift rod, or assist cylinder, or what? Does the prop shaft move in and out as you move them or not? It's been 40 years since I've had one apart, but for some reason, I seem to remember the drive shaft and pinion need to come out first. Can't tell you just why at the moment. But I'll ponder on it.
 
The lower part of the shift rod in the assisit cylinder moves up and down about 1/8". The assisit cylinder barely moves. The prop shaft moves in and out about 1/8" as well. The pinion gear cant really come out first as the clutch dog is directly below the nut for the pinion gear. And besides the forwars gear is not secured to the prop shaft anyway.
 
Accept the fact that the pinion can be taken out first.----That operation MUST in fact be done on newer motors.----I say the bottom of the shift servo rod is damaged and not coming through the hole in the pump body.
 
My motor is a 1976. This screenshot is directly from the repair manual from seloc marine. The pinion gear comes off after the prop shaft is out. I would agree something is damaged inside or siezed. But I dont know how to go about getting it out without completely damaging everything. Seeing as some of the parts in there I might have a really hard time finding.
Screenshot_20200904-114334_Chrome.jpg
 
Sorry----The pinion gear can be taken out first.----I have a half dozen of those lower units kicking around.----I am not working on my first one here.
 
Why does it need to come out first if the forward gear is not going to come out with the prop shaft? I dont need the drive shaft out at this moment. I need the shift rod and assist cylinder to come out. Thats my problem. You can barely get a wrench onto the nut for the pinion gear.
 
It does not need to come out now.----It can be taken out now.------But it has to come out later to replace the bearing above the pinion.----I am not working on my first one.---End of the story.
 
I know it has to come out later. Thats fine. But that can happen when I finally get the prop shaft out. I dont care that its possible to come out now. Thats not a concern at the moment. The stuck shift rod is the problem, not the fact of weather or not the pinion can come out first or not.
 
OK, I dug out a factory service manual, admittedly a 1974, but (?) Anyhoo, it does say remove the prop shaft and assist cylinder first and simultaneously. THEN the pinion gear and drive shaft. Then the forward gear, then oil pump.

It would seem the assist cylinder is somehow seized in the gearcase. I have no clue how or why.

That's all I have to offer. After all, it has been 40 years.
 
I just talked to an old boat mechanic and he said it sounds like the only way its coming out now is for something to break. So I might be looking for a new lower unit/motor or boat.
 
I dont want to break anything extra. Im putting it back together and going to sell it. If someone wants to try to fix it they can. Ill buy a different boat with a proper working engine.
 
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