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1996 Mercury 115hp 4 cyl. Shift Shaft Issue

C

captcrabbin

New member
I went to replace a leaky shift shaft bushing and seal, and in the process accidently pulled the shift shaft from the lower unit. After a wholly s**t, I placed the shaft back into the cam but now it's freely spinning. I have the engine in reverse, as a recommendation from a mechanic, while replacing the impeller kit and bushing/seal. I drained all the gear oil and can see where the shaft sits in the cam but there is nothing locking it in place. The prop and driveshaft have not moved. I cannot afford to purchase a new lower unit, any advice?
 
You're going need to pull the bearing carrier with the reverse gear and the prop shaft and reinstall the shift cam in the correct orientation and reinsert the shift shaft. Its not that bad of a job. How do you know you put the shift shaft back in the cam? Most times, the cam falls to the bottom of the gearcase.
 
fitz73222 said:
You're going need to pull the bearing carrier with the reverse gear and the prop shaft and reinstall the shift cam in the correct orientation and reinsert the shift shaft. Its not that bad of a job. How do you know you put the shift shaft back in the cam? Most times, the cam falls to the bottom of the gearcase.
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Here's what I see. The shaft slides into the cam insert but there is no resistance. I think there is no other option then to pull all the gears and prop shaft. If it's not that bad of a job, would the service manuals provide enough instruction to do this myself? Thank you!

LU Image.jpg
 
Familiarize yourself by looking at the parts diagrams to better understand the names of the parts and how it is put together, all available on this website. You just need your serial number. The only "special" tool you'll need is the puller to remove the bearing carrier after you remove the two bolts that secure it in place. Is this a fresh or saltwater motor?
 
fitz73222 said:
Familiarize yourself by looking at the parts diagrams to better understand the names of the parts and how it is put together, all available on this website. You just need your serial number. The only "special" tool you'll need is the puller to remove the bearing carrier after you remove the two bolts that secure it in place. Is this a fresh or saltwater motor?
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Saltwater engine. Thank you!
 
Reason I ask is that sometimes you have to heat the bearing carrier with a MAPP Gas or propane torch on the outside gear housing to expand the housing away from the carrier to be able to pull it with relative ease. Saltwater can be stubborn about coming apart. Your gearcase design is typically much better about coming out than earlier Mercury gearcases.
 
fitz73222 said:
Reason I ask is that sometimes you have to heat the bearing carrier with a MAPP Gas or propane torch on the outside gear housing to expand the housing away from the carrier to be able to pull it with relative ease. Saltwater can be stubborn about coming apart. Your gearcase design is typically much better about coming out than earlier Mercury gearcases.
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I appreciate all the info you provided. Going to study this for a little bit and dive in. I'll keep you posted. Thanks again.
 
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