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DF115 2003 Reverse gear grinding
Have a 2003 DF115 that will not engage the reverse gear (The engine have 2600 hours on it). It only gave grinding noise and never went into reverse gear. Forward has also been problematic from time to time, but very rare. First, I dismantled the lower unit, found nothing suspicious (clutch dog, bearings, everything looked fine to me), put it back together and it worked just fine, for one day only... Next day the problem was back. Took it apart again and now I discovered a bronze colored ring inside forward gear was on it's way out behind the gear. Suspected it was blocking the clutch from moving freely back and forth, so I glued it. Put the unit back together, same story, worked flawlessly for one day only. Took it apart again and the ring was still in place, confirming it was not the problem. Prior to this I checked cables and it seemed to be working, but after talking to several mechanics which insisted on the cables I did a more thorough check and found the Remote Control Box was not moving as far back and forth as it should. Changed both the Control Box and the cables just to be sure. Now, it is still unable to engage reverse, just grinding. But, I have discovered something peculiar, when I take the boat out on the water and run it at speed for a few minutes it suddenly shifts without a hassle, just clonk into reverse with ease. As if when the lower unit warms up it changes everything. I have confirmed this behaviour trough weeks now, when the lower unit have been put to work for some minutes it shifts without a problem.
Things to be noted: 1. With the lower unit and the shift cable off, the shift lever moves freely, no resistance at all. 2. With only the cable off, motor running trying to shift "manually", it takes considerable force to put it into reverse with your hand on the shift lever (lower unit cold). Forward is easier. 3. There is a little bit of free movement/slack in the shift lever, but not more than a millimeter or so. 4. With the lower unit off, on the bench, shifting by turning the shift rod by hand while rotating the prop shaft is nearly effortless.
Any ideas?
Things to be noted: 1. With the lower unit and the shift cable off, the shift lever moves freely, no resistance at all. 2. With only the cable off, motor running trying to shift "manually", it takes considerable force to put it into reverse with your hand on the shift lever (lower unit cold). Forward is easier. 3. There is a little bit of free movement/slack in the shift lever, but not more than a millimeter or so. 4. With the lower unit off, on the bench, shifting by turning the shift rod by hand while rotating the prop shaft is nearly effortless.
Any ideas?
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