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Shifting issue

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Wayne S

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Hello, I have searched and searched but no luck so I will ask. I have a 1979 Evinrude 35hp, # 35903A. I purchased this last winter and when I put it on the boat this year and took i t out I learned it needed a clutch dog. I was finally able to find one after looking for two months. I put everything back together and all seemed fine. This would be the first time I ever attempted anything outboard related. I do have decent mechanical ability just no experience with outboards. Anyway it is now worse than when I started with the old clutch dog. Not sure but my issue may be in shift rod height. Listening to someone on a different board I was told this shift rod gets tightened all the way that I don't have to set it to a height. It seems to me if I were to set it any higher it would just make the issue worse. It won't even stay in gear if I shift it by hand on the water. When I had it hooked up to the cable it won't even more far enough to put it into forward gear. When looking at it, when I shift it into forward I have to shift way post where it should sit in the shift lever lock (lock lever, whichever) It actually sits and the next high spot. I will try to ad attachments to help explain. I really think it is just something simple and my lack of experience is killing me.

NOTE: I just tried to upload some pictures and couldn't make it happen. I will see if my wife can do it when she gets home. Until then any help would be greatly appreciated.
 
No shift rod height adjustment.-------Is the brass connector properly assembled ?----No adjustment there either !----Did you inspect forward gear dogs ?-----Adjustment is at the shift lever on the motor.------Best to start over before you damage the new clutch dog.
 
I took the lower unit back apart and everything in there is good. I figured I would go through all the steps again and see what i come up with. I started thinking maybe I didn't connect the upper shift rod properly. My eyes are getting old so I brought a light and reading glasses with me. When I put the shift rod into the brass coupler it just didn't look big enough. I installed the bolt and tightened real tight. It would shift with no issue while just sitting there so I took it to the water. 2 to 3 seconds of throttle and slipped out of gear. Same as before it would no longer shift far enough to get back into gear. I took the little plate off where the connection is and I could see that the upper shift rod was pulled partially out of the brass connector. You can tell because it is rubbed clean. It seems to me that the indent to keep the bolt in place at the connector is worn somehow and too small to keep the upper shift rod in place. I hope I did it correctly, I added a photo where you can see an area rubbed clean. That area is the upper shift rod and is not exposed when the shift rod is in its proper position.

Edit: I am going to take the lower unit back of today if weather allows. I want to inspect the brass connector. It makes more sense that the connector is worn since it is brass. I don't see brass as wearing out the shift connector. Am I right?
 

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I understand that. It wouldn't make sense to do it any other way. That is my point. It is slipping out of that position. I had my light and reading glasses and with them I could see that the shift rod was all the way into position. I installed the bolt. When shifting it at home it worked fine but there is no pressure on a none running motor out of the water. So I took it to the river and within seconds it slipped out. When I got home I could see that the shift lever was out of the coupler by a 1/4" or more. I am certain this is the area of issue, just whether it is the shift rod itself or the coupler. I am assuming it is the coupler. But just to recap. The shift rod was in place when I put the bolt in and tightened it.
 
I am going to try and add one more photo/ I took the lower unit off and you can clearly see where the threads of the bolt grooved the shift rod. It is most visible at the top of the higher part of the shift rod (based on picture orientation). I do not think I could have tightened the bolt any more without stripping the brass. I don't know if I should be getting a new connector or should I be thinking upper shift rod?
 

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Remove the connector and turn it end-for-end (upside down, so to speak). Reinstall it rotated around as much as you can and still get the bolt in. Now the bolt will intersect a cleaner spot on the shift rod.

Personally, I suspect that is only part of the problem though.
 
Sounds good I will give that a try. You may be right that it is only part of the problem. I hope you are wrong but I can't bet against it. Thanks
 
when you inserted the clutch dog, did the rounded ends "snap" into place onto the "U" shaped slider piece (In think it's called the cradle)? I have not worked on this specific outboard but did notice that on the two smaller vintage evinrudes I worked on. You can easily think the clutch dog is sitting properly but it has to mate solidly with the cradle piece.
 
I did feel for that and it was pretty positive connection. Like it snapped or clicked into position and held it while I installed it.
 
Wayne S said:
I am going to try and add one more photo/ I took the lower unit off and you can clearly see where the threads of the bolt grooved the shift rod. It is most visible at the top of the higher part of the shift rod (based on picture orientation). I do not think I could have tightened the bolt any more without stripping the brass. I don't know if I should be getting a new connector or should I be thinking upper shift rod?
Click to expand...

That looks a bit banged up but I think it's still usable. How does inside of brass connector look?
 
The inside of the connector looks fine. I couldn't even see a worn area. It doesn't look out of round. I thought I use enough torque when I tightened the bolts but maybe I need to crank it more. I was just trying to be cautious and not strip the brass. I am gonna really crank it on there and see how it turns out. If I have to buy a new brass piece it is only $22 but the bolts are $7 each (lol). Hopefully the shift rod is still good, I get the feeling that is a bit of a project. Thanks
 
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