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Mariner 100HP 4 Cylinder 1988, would not shift

H

Howard Luo

New member
Hi, 1st post on this forum,Mariner 100HP 4 Cylinder 1988 -93 (exact year unknown)

Problem is after changing shift shaft seal (due to excessive amount of water/exhaust oil in gear box, changed water pump gasket, driveshaft seals, shift shaft seal), it wouldn't shift and leave me only forward gear. The reason might be when I pull open the shift shaft bush to replace the seal, the shift shaft pop out and disengaged with shift shaft cam. It's said need to be tear apart all the gear box and do the alignment and assemble again.

Before I do it, I'd like to seek advice from you all who has experience in that. How I can dismantle drive shaft? propeller shaft, anything need to be very careful at? I'm trying to get the tools to pull the propeller shaft bearing carrier now . Kind of heard some people said need a proper torque to dismantle pinion gear.

Thanks
 
When you pulled out the shift shaft, spring pressure from the shift clutch assembly pushed the shift cam to the front of the gearcase. There are 2 ways to fix the problem, you can take the gearcase apart by pulling the (2) nuts that hold the reverse bearing/propshaft carrier assembly into the case, then pull the propshaft & carrier out with a slide hammer or other suitable method. Then you can locate the shift cam and properly assemble the shift shaft to the cam. Then reassemble the gearcase with a new O-ring on the bearing carrier. And perhaps take a look at the propshaft seals at the same time, since they're easily replaced with the carrier out & propshaft removed from the carrier.

There is another way, that doesn't require disassembly.

Here's a detailed posting on that method:

http://forums.iboats.com/forum/engi...stalling-shift-shaft-into-lower-unit?t=264376

Hope that helps, G'luck.........ed
 
Thanks Ed, it's very helpful.


I am in the progress of pulling out the bearing carrier, found it is very stubborn. I couldn't find the tool, So I made one out of chain but the hook that is made by cutting a chain cannot hold the carrier arm properly and it always misaligned. I also tried heat where the carrier contacts the casing with butane torch to close 100 Degree Celsius, but no luck.


I cut 2 "quick-connection" and seems better hold the arms, will try again this weekend with heat and update.


I haven't tried the alternative method yet, and I also want to look at the gears to see any abnormalities as the drain out oil from the gear case just like black ink, assume leakage but not understand why it's black and smelly.
 
Hi Ed,
I had no luck to pull the bearing carrier open even with the help of a mechanic with heating (He didn't suggest any more work on it as it seized and that cheaper to buy another lower unit). I tried the method that doesn't require disassemble,I rotated the prop shaft clockwise just before the "click-clang" sound, then I tilted the lower unit, i can hear the sound of some metal piece moving. I just don't know how to get the shift cam back into position as I even couldn't see where it is even though I've wobbled the gear case a few times, any suggestions and ideas are appreciated.

Cheers
 
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