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Optimax lower unit stuck in gear

G

gizmolvr

Contributing Member
2005 optimax 115 with 25"

2005 optimax 115 with 25" shaft. Unit is stuck in gear. Tried moving from engine and shift linkage moves freely and can see shift rod moving above lower unit. Any ideas?
Motor is sitting on engine stand and is not hooked up on boat.
 
"John, could be one of a few t

"John, could be one of a few things - start with the easiest first.

Is there oil in the lower unit? Is it clear (looks like oil) or is it milkly, full of water, have metal shavings or worse, metal bits present?

If the shift rod appears to be operating correctly, at the bottom of the rod is a shift cam and a follower that need to work together to push another rod (stubby horizontal one that engages the clutch) to change gears - any could be broken or the clutch spring could be shot.

All except checking the oil would require disassembly of the lower unit."
 
"Graham,
Thanks for the respo

"Graham,
Thanks for the response. I will check the oil tomorrow. If it is not the oil, what kind of expense could i be looking at? Thanks"
 
and what level of expertise is

and what level of expertise is needed to repair? I do have the shop manual. Thanks
 
"Basically, if you can use a w

"Basically, if you can use a wrench and a screwdriver you can repair an outboard. The lower unit is more like a jigsaw puzzle. You just have to put it back together correctly and it will work fine.

And while you will get varying opinions, I find Seloc's manuals more than sufficient for both powerhead and lower unit repairs (but to be fair do own a complete set of service manuals as well) - giving quite detailed tear down/reassembly instructions.

If you do decide to tear it open, in addition to whatever you find wrong you will want to get a new seal kit. No matter how careful you are some of the rings/seals will get destroyed.

But even if you are not overly mechanically inclined a lower unit tear down/rebuild can easily be done over a weekend."
 
Sorry forgot to address your &

Sorry forgot to address your "expense" question.

Depends what is shot. A cam follower can run 200 bucks - clutch is about the same while a clutch spring is less than 2 bucks...

A seal kit is about 65 bucks...
 
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