DT150 Super Six Shifting Issue

[ribasshound]

This is a little lengthy, sorry but trying to give all info I can on my 89 DT150 Super Six.
Took boat out for a second time about a week after rebuilding and replacing fuel pumps. Had no issues the first time out.
This time, after running a while with no issues and fishing for a little while, I started motor and placed it in forward gear. I heard a "clunk" and...no gears, just engine revving. I could move the shift forward and backward with no engagement of gears.
I brought home and ran on muffs in driveway. The prop was spinning in neutral and forward but not in reverse (NOTE: shifting was a little stiff). I turned motor off and found I found prop would spin freely in reverse but would spin and "click" few times then lock up in neutral and forward.
I disconnected the cable and it moves smoothly. Checked for alignment to linkage and it is fine.
During a fishing tourney Saturday I started motor to charge batteries and boat was propelled forward (IN NEUTRAL!) i turned it off and started again, no forward this time just neutral idling.
Today at home with cable disconnected and motor running (on muffs) I manually shifted to each gear. I found I had to put a little muscle behind each attempt.
I sampled lower unit oil and it is clean...no metal shavings.
ANY HELP IS APPRECIATED!

[Solarman]

It sounds to me like when put back together, something is binding? Is the linkage in the midsection loose or binding? The linkage under the powerhead?
Did you work on the gears in lower unit?

Post back when able.

[ribasshound]

Just rebuilt fuel pumps. Did not touch anything else. I was running around local fishing spot after rebuild and stopped to troll. When I started motor and placed in forward I heard the "clunk" noise. At that point I had no gears.
At the ramp., out of the water, I was able to spin the prop in reverse. Both forward and neutral prop locks up (in gear).
With linkage disconnected and on muffs I am able to maunally move gear selector (somewhat stiff) between gears but again prop spins in reverse and locks up in neutral and forward. Cable moves freely when disconnected but is stiff when connected and running.
Started motor on water to charge batteries after trolling around for a few hours and boat was propelled forward while in neutral.
Motor idles, no problem

[seaox230c]

when you shift from fwd/neu/rev make sure the shift linkage at the lower end connection point moves properly, the inbd control rod moves the shifter assy thru several linkages some of them are plastic make sure none are broken. If all that works then the issue might be inside the clutch rod shifter assy

[Solarman]

If nothing else has been changed/rebuilt then I'm thinking you may have a problem in the shift clutch assy also, as seaox said (located in the lower unit). If something broke, it is wise not to run until repaired.

Good luck, post back if you find out anything.

[ribasshound]

ANNYBODY??? Thoughts

[ribasshound]

Sorry for last post, thread wasn't updated yet