Alpha Drive Unit Service Section 3E - Shift Cable
Contents
1. b Roller 91 865232 d Gasket 90 899907001 JULY 2006 Page 3E 9 Shift Cable Installation Drive Unit Installation and Shift Setup 15 Position drive unit shift shaft so that it is straight forward by turning shift shaft clockwise while simultaneously turning propeller shaft counterclockwise a Drive unit shift shaft IMPORTANT Install right hand or left hand drive unit on the appropriate transom assembly when making dual engine installations The left hand rotation drive unit can be identified by the decal on the back side of the upper drive shaft housing which states Alpha One Counter Rotation 16 Install sterndrive unit as follows a Position trim cylinder straight back over top of acceleration plate Be careful not to scratch acceleration plate or trim cylinders b Guide U joint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into driveshaft housing Ensure that shift slide remains upright and engaged with bell housing shift shaft lever c If necessary rotate propeller shaft counterclockwise slightly to help align U joint shaft splines with engine coupler splines while sliding sterndrive into bell housing IMPORTANT If drive unit will not slide into bell housing ensure that the shift shaft and couplers are positioned properly Do not force drive unit into position a Gasket b Shift slide Remove Shift Slide Stabilizer Tool Slide sterndrive all the wa2. NPSF tap This special Straight Thread Tap may be obtained thru Quicksilver by ordering 91 95639 The following important information must be observed when performing tapping operation e Tapping must be done from the front bellows side end of bell housing to prevent cross threading e Never use a Tapered Thread Tap as improper positioning of shift cable may result or water may leak into bell housing SST Old style shift cable New style shift cable a Shift cable retaining nut 22927 Threading shift cable hole in bell housing older models to accept the new style shift cable a 1 4 18 NPSF Tap 91 95639 Page 3E 2 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup 22929 Old style cable installation New style cable installation a Drive Unit Shift Cable Removal and Installation Tool 91 12037 MerCruiser I l R MR Alpha One New Style Aft Shift Cable Conduit and Core Wire Identification Transom assembly serial number 0C698141 and above A new style drive unit shift cable is being used Following is a list of the major differences from the earlier cable IMPORTANT The new style shift cable is pre cut to proper length and should be replaced as an assembly only Do not mix parts between old and new style 1 Larger diameter armor wrapped core wire Figures 1 amp 2 2 Larger diameter hole in shift cable anchor Figures 3 amp 4 3 Larger diameter
3. adjustment procedure 11 After remote control shift cable has been properly adjusted reinstall cable and shift assist assembly if applicable and secure with hardware as shown With Shift Assist Assembly a Remote control shift cable b Shift Assist Assembly c Clevis pin and cotter pin d Large I D washer e Small I D washer and cotter pin older models locknut tighten until bottomed then back off 1 2 turn There should be no pressure on either side of the shift assist assembly attaching point Failure to adjust properly could apply excessive load to the cable and cause the throttle only portion of the control to hang up and malfunction 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup If the shift assist assembly requires effort to fit over the anchor stud and clevis pin the shift cable from the control box is adjusted incorrectly Remove the shift cable and reposition the adjustment barrel as required to allow the shift assist assembly to be attached with no effort KP 22996 Without Shift Assist Assembly a Remote control shift cable b Clevis pin with cotter pin not shown c Spring existing d Washer existing e Large D washer f Spacer g Small I D washer existing h Cotter pin older models locknut tighten until bottomed then back off 1 2 turn IMPORTANT If an extra long remote control shift cable is used or if there are a large numbe
4. hole inside of shift slide Figures 5 amp 6 4 Larger diameter shift cable conduit to accommodate larger diameter core wire Figures 7 amp poeesia Figure 1 Older core wire a 1 9 mm 075 in 22932 22931 Figure 2 Newer core wire a 2 54 mm 100 in b New pre cut core wire dimension 1832 mm 72 1 8 in c Front edge of anchor 90 899907001 JULY 2006 Page 3E 3 Shift Cable Installation Drive Unit Installation and Shift Setup Se X N I A N A a S E X N IDR A NT N RA X R A X Y A A A ee ee ee AX 7 L ST mA 22933 Figure 3 Older cable anchor a 1 98 mm 07871 in oe C O cP if N SS SS A S eee X ZN NS 1 P D 22934 Figure 4 Newer cable anchor a 2 62 mm 103 in ees 22935 Figure 5 Older shift slide a 1 98 mm 07871 in 22936 Figure 6 Newer shift slide a 2 62 mm 103 in Page 3E 4 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup 22937 Figure 7 Older shift cable conduit a 7 62 mm 300 in NOTE Inner core wire is cut to length at installation 22938 Figure 8 Newer shift cable conduit a 8 25 mm 325 in NOTE Inner core wire is pre cut by factory NOTE The distance from the centerline of the cable end guide to the centerline of the brass barrel was changed in 1974 hh o 22939 1973 and prior adjustment dista
5. Shift Cable Installation Drive Unit Installation and Shift Setup Alpha Drive Unit Service Section 3E Shift Cable Installation Drive Unit Installation and Shift Setup Table of Contents MerCruiser Drive Unit Intermediate Shift Cable Alpha Drive Unit Remote Control and Drive Unit Shift Kosyaydii ers 1 0 a rr 2 Cables Adjustment Drive Unit Installed 12 MerCruiser I I R MR Alpha One New Style Aft Shift Checking Alpha Plunger Type Shift Cutout Switch Cable Conduit and Core Wire Identification 3 PUMA Ge etesas ctseiet oss seeeeieen ie aa adendesecenctnudepasedsccue 20 Alpha Sterndrive Installation ccccccceseeeseeeeees 6 Checking Switch Operation ee e eee 21 Trim Cylinder installation eee eee 11 Newer Style Alpha Shift Plate eee 22 Attaching Speedometer Water Tube from Gimbal Newer Shift Levers for Alpha and Bravo 22 Housing to Alpha Sterndrive ccsccesseeseeeeeeees 11 90 899907001 JULY 2006 Page 3E 1 Shift Cable Installation Drive Unit Installation and Shift Setup MerCruiser Drive Unit Intermediate Shift Cable Identification Transom assembly serial number 6376504 and above IMPORTANT This newer style cable which attaches to bell housing from aft end can be used on models with the old style shift cable attached on front side of bell housing To do this the threaded hole in bell housing must be tapped all the way through using a 1 4 18
6. itch positioned in adjustment notch b Shift interrupt switch Both switches are now located in slots There is a machined rib formed in the shift plate at each side of the switch These ribs form a channel that allows the switch to move towards and away from the actuator without any side play Switch adjustment is made easier and more accurate In gear switch There are two notches on the shift lever The one used during engine operation is just behind the shift lever parallel to lever A second adjustment notch is provided as shown above The shift lever is rotated counter clockwise to bring the second notch in contact with the In Gear Switch This second location allows you to have direct access to the switch mounting screws You can make a switch adjustment without having to move the shift lever out of the way This allows for a more accurate adjustment This switch must be adjusted so that the switch plunger is set at zero clearance plunger is just making contact with the bottom of the adjustment notch in the shift lever Shift interrupt switch The shift interrupt switch and the actuating hardware are the same components that were used on the previous shift plate This switch must be set so that the switch plunger is 0 8 mm 1 32 in from the bottom of the notch in the shift actuation arm Newer Shift Levers for Alpha and Bravo Page 3E 22 T 21499 Dual gear indicator switch detents have been added so that lever can be m
7. l and Drive Unit Shift Cables Adjustment Drive Unit Installed IMPORTANT Shift cable adjustment for a right hand RH rotation drive unit is different than the procedure for adjusting a left hand LH rotation drive unit Be sure to refer to the appropriate procedure when performing the following steps Right hand rotation Install control cable in remote control so that cable end will move in direction A when shift handle is placed in the forward position Left hand rotation Install the control cable in remote control so that cable end will move in direction B when shift handle is placed in the forward position lt B 6614 IMPORTANT Drive unit must be installed IMPORTANT Do not run engine Page 3E 12 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup 1 Remove remote control shift cable and shift assist assembly if installed With Shift Assist Assembly a Shift Assist Assembly b Remote control shift cable 22984 Without Shift Assist Assembly a Remote control shift cable IMPORTANT If boat is being equipped with a remote control that has separate shift and throttle levers the shift assist assembly that is shipped with the engine should not be used The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly A Spacer Kit 23 11284A1 will have to be ordered to connect the remote control shif
8. nce a 14 9 cm 5 7 8 in b Brass barrel 7 DT 22940 1974 and newer adjustment distance a 15 2 cm 6 in b Brass barrel 90 899907001 JULY 2006 Page 3E 5 Shift Cable Installation Drive Unit Installation and Shift Setup Alpha Sterndrive Installation Page 3E 6 1 Remove trim cylinder support and dust cover from bell housing studs Retain elastic stop nuts and flat washers Typical a Dust cover b Trim cylinder support 2 Remove gear lube monitor cap Fill with lubricant Mei _ gt E NASE SJ 7850 b OPERATING RANGE line High Performance Gear Gear lube monitor 92 802854A1 Lubricant 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup 3 Push dribble valve stem in until gear lube appears a Dribble valve stem 4 Once gear lube appears release dribble valve stem 5 If the gear lube monitor is below the full line Fill the gear lube monitor to the OPERATING RANGE full line with specified fluid Do not overfill 6 Install the gear lube monitor cap Ensure that the rubber gasket is inside the monitor cap Do not overtighten the cap IMPORTANT Rubber gasket must be properly positioned and glued in bell housing bore before installing drive unit or water may leak into boat 7 Ensure that rubber gasket and water passage O ring are properly positioned in bell housing The rubber gasket must be glued in place or
9. ntrol shift handle into full reverse position Clutch should engage before shift lever comes to a stop If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with reverse gear Retighten stud Shift remote control several times and stop in reverse to recheck shift cutout switch position Roller or plunger pin must be centered Page 3E 19 Shift Cable Installation Drive Unit Installation and Shift Setup b Left hand LH propeller rotation drive unit While turning propeller shaft clockwise move remote control shift handle into full forward position Clutch should engage before shift lever comes to a stop If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with forward gear Retighten stud Shift remote control several times and stop in forward to recheck shift cutout switch position Roller or plunger pin must be centered 22987 a Adjustable stud Checking Alpha Plunger Type Shift Cutout Switch Timing 1 While holding the retainer nuts on the back of the shift plate for older plates on newer plates just loosen screws loosen the two phillips head screws on the shift cutout switch and slowly move the switch either forward or aft 22997 a Switch plunger pin b Two screws c 1 32 adjustment gap d Activating lever assembly Page 3E 20 90 899907001 JULY 2006 Shift Cable Installation Drive Uni
10. on remote control shift cable end guide to remove slack from remote control and cable and adjust brass barrel as necessary to align attaching points with shift lever clevis pin hole and stud Be sure to maintain light pressure on drive unit shift cable 22989 a Shift lever clevis pin hole C Stud b Remote control shift cable end guide d Brass barrel 6 Ifthe shift plate is equipped with a Shift Assist Assembly then skip this step and go to step 7 a Ifthe shift plate does not have a Shift Assist Assembly then follow these instructions NOTE Two different size threaded ends have been used on the remote control shift cable 90 899907001 JULY 2006 Page 3E 15 is Shift Cable Installation Drive Unit Installation and Shift Setup b After cable has been aligned turn brass barrel 2 turns away from cable end guide on 1 4 28 threaded ends and 4 turns away from cable end guide on 1 4 40 threaded ends a J L E NS Te Foor N a End guide 22991 b Brass barrel 7 Temporarily install remote control shift cable on stud and install clevis pin m Je E CE T 1 L HE Let S a Remote control shift cable 22993 b Clevis pin 8 Shift remote control as stated in a or b following older control shown a i i position Right hand RH rotation drive unit reverse gear past detent into wide open throttle Page 3E 16 90 899907001 JULY 2006 Shift Cable Installation Dri
11. oved from run position to set position for adjusting switch lever moves out of the way of the adjusting screws and switch plunger can also be viewed ALPHA and BRAVO stamped on individual levers for identification 90 899907001 JULY 2006
12. r of bends in remote control shift cable or remote control has inadequate output travel an additional adjustment may be necessary Refer to step 12 or 13 as applicable 12 Remote control with single lever shift throttle control a Right hand RH propeller rotation drive unit Shift remote control into reverse gear wide open throttle position while simultaneously rotating propeller shaft clockwise Clutch should engage and cause propeller shaft to lock If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with reverse gear Retighten stud Shift remote control several times and stop in reverse to recheck shift cutout switch position Roller or plunger pin must be centered Left hand LH propeller rotation drive unit Shift remote control into forward gear wide open throttle position while simultaneously rotating propeller shaft clockwise Clutch should engage and cause propeller shaft to lock If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with forward gear Retighten stud Shift remote control several times and stop in forward to recheck shift cutout switch position Roller or plunger pin must be centered 13 Two lever remote control with separate shift and throttle levers a 90 899907001 JULY 2006 Right hand RH propeller rotation drive unit While turning propeller shaft clockwise move remote co
13. t Installation and Shift Setup 2 Adjust switch to locate plunger pin to 0 8 mm 1 32 in between plunger pin and activating lever assembly 22998 a 1 32 in drill bit 3 Slowly move activating lever assembly off until cutout switch opens or closes Circuit should open or close when the activating lever assembly is moved 4 8 0 8 mm 3 16 1 32 in Measure with 152 mm 6 in steel rule 22999 a Cutout switch b Movement of activating lever assembly c 152 mm 6 in steel rule 4 After adjustments are made and are within 4 8 0 8 mm 3 16 1 32 in tighten the screws on the cutout switch After tightening screws recheck the plunger pin position CHECKING SWITCH OPERATION 1 Reconnect throttle cable s removed earlier 2 Place boat in water and start engine Check the following a Shift into forward and reverse gear making sure that clutch engages before engine begins to accelerate Accelerate engine in forward and reverse gear to ensure engine does not shut down c Check that shift cutout switch plunger is centered in notch of shift cutout lever with drive unit in forward and reverse gear d Shifting from IN gear position to neutral ensure drive unit is in neutral before remote control shift lever comes to neutral detent position 90 899907001 JULY 2006 Page 3E 21 Shift Cable Installation Drive Unit Installation and Shift Setup Newer Style Alpha Shift Plate 23000 a In gear sw
14. t cable when shift assist assembly is not used Wa NE 7 U YANCY VVA Y NA 22985 a Clevis pin with cotter pin not shown c Spacer b Large I D washer d Small I D washer and cotter pin 90 899907001 JULY 2006 Page 3E 13 Shift Cable Installation Drive Unit Installation and Shift Setup 2 Ensure shift lever adjustable stud is at bottom of slot If necessary loosen stud and move it to bottom of slot then retighten stud 22987 a Adjustable stud 3 Shift remote control as stated in a or b following a Right hand RH rotation drive unit forward gear past detent into wide open throttle position 7807 b Left hand LH rotation drive unit reverse gear past detent into wide open throttle position 4 Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel this removes all slack from the cable Page 3E 14 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup IMPORTANT Do not use excessive force when holding pressure on the drive unit shift cable Excessive force would be indicated by movement of the shift cutout switch 22988 a Drive unit shift cable push in b Propeller shaft rotate counterclockwise 5 Lightly pull
15. ve Unit Installation and Shift Setup b Left hand LH rotation drive unit forward gear past detent into wide open throttle position c Simultaneously rotate propeller shaft clockwise until shaft stops to ensure full clutch engagement k 7870 9 Perform a or b as appropriate a On models with earlier type switch Check shift cutout switch lever position Roller must be centered a Shift cutout switch roller 90 899907001 JULY 2006 Page 3E 17 g Shift Cable Installation Drive Unit Installation and Shift Setup Page 3E 18 b On models with later type switch Check shift cutout switch plunger position Pin must be centered Information on checking plunger type cutout switch timing is found at the end of these instructions a Shift cutout switch plunger pin 10 If roller or plunger pin is not centered a b NOTE Ensure adjustable stud is at bottom of slot in shift lever Check remote control for proper shift cable output 76 3 mm 3 1 8 in Refer to Installation Requirements If a and b are correct ensure drive unit shift cable is not crushed or kinked If drive unit shift cable is binding the shift cutout switch roller or plunger pin will move off center when shifting into and out of forward and reverse If shift cable was damaged during installation install new shift cable assembly in accordance with instructions contained in sterndrive service manual Then repeat shift cable
16. water may leak into the U joint bellows and then into the boat O ring must also be glued in place 8 Coat bell housing studs with lubricant a Rubber gasket b Water passage O ring uas eae Bell housing studs 92 802859A1 90 899907001 JULY 2006 Page 3E 7 Shift Cable Installation Drive Unit Installation and Shift Setup 9 Grease sterndrive U joint O rings and drive shaft splines A grease packet for this procedure is provided with the sterndrive packaging b Drive shaft splines Engine Coupler Spline Grease Jone R liaa 92 802869A1 N a a U joint bellows Page 3E 8 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup 11 Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft Do this by placing remote control shift lever in Forward gear position for RH drive or Reverse gear position for LH drive unit a Shift shaft c Shift slide b Shift shaft coupler d Slot IMPORTANT Shift slide assembly is free to rotate on core wire Ensure that shift slide remains in upright position and is properly engaged with shift shaft lever roller while installing drive unit 12 Engage shift shaft roller into shift shaft lever 13 Place gasket on bell housing 14 Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide a Shift shaft lever c Shift Shaft Slide Stabilizer Tool
17. y into bell housing Page 3E 10 90 899907001 JULY 2006 Shift Cable Installation Drive Unit Installation and Shift Setup L Secure sterndrive to bell housings using fasteners as shown Torque the fasteners a Locknut and flat washers b Locknut and continuity circuit washer no flat washer at this location C H SCC 17 Return remote control shift lever to the neutral position Trim Cylinder Installation 1 Install trim cylinders on aft end of sterndrive unit with hardware as shown 2 Install the plastic caps by snapping in place NOTE Upon installation of hardware apply lubricant to all components except plastic caps Py f CASSI 7849 a Aft anchor pin d E ring clips b Bushings e Plastic caps c Flat washers aig aauianiiiiai Trim cylinder hardware 92 802859A1 3 Position the sterndrive unit serial number decal Attaching Speedometer Water Tube from Gimbal Housing to Alpha Sterndrive 1 Raise drive to gain access to area between gimbal housing and sterndrive immediately above the transom end of the anti ventilation plate 2 Align plastic slots on male and female portions and insert 90 899907001 JULY 2006 Page 3E 11 9 Shift Cable Installation Drive Unit Installation and Shift Setup 3 Push down to secure 22975 a Male end of speedometer tube fitting b Female portion SZ a 22977 a Tube fitting male end b Topside portion female end Alpha Drive Unit Remote Contro
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