New Drive - Popping out of gear in forward and no reverse
 

Just installed a freshly built Bravo and have an interesting problem. When running on the hose I shifted into forward (either with the shifter or just the cable by hand) there is a clunk and it will begin to spin. After 5 secs or so it will disengage. If left in gear it will re-engage on its own and would probably keep repeating the process. Also, shifting to reverse does not do anything, does not appear to even try to engage.

Tearing the rear cover off tonight, looking for some input on what to look for. Spring and check ball sound like a possiblity, anything else???? Any adjustments internal to the drive I should look at?

This appears to be a real solid build (tower, etc) that has been sitting so I hope it is something simple. All suggestions appreciated.

Its either a bad cone clutch or the cable is way out of adjustment. If it was the ball/spring detent assembly, it would be very hard to shift or wouldn't shift at all.

Damn, not what I wanted to hear...

I was shifting the cable driect from the drive by hand, not to mention it worked for the previous drive so I doubt the cable will be the issue.

Remind me, can a cone clutch be swapped out without pulling the drive? I plan to pop the top and rear covers off to see what's up, would be great if I didn't have to go any further into it.

Come to think of it, even shifting by hand at first it would only shift between neutral and forward, would not move toward reverse at all. Maybe there is still hope for the ball/spring.

I'm guessing its the clutch cone also...had a simular thing myself once.

Are the nuts on the shift cam on the top, or bottom ?
( item #12 in this pic)
http://www.mercruiserparts.com/Show_...%28STANDARD%29

If they're not on the bottom, they wont shift right.

Are the gears timed right ( + on one - on the other,
not + + or - - ) when viewed from the back ?

Heading to the shop in just a few. Should know more once I pull the caps.

The cone clutch is only available when purchasing an entire upper gear set.

Cone clutch is sold seperate if it is the new X gears. The drive needs to be pulled down to replace it.
I am thinking ball and spring.. but check to see if the cam moves properly when shift.. Remember the input shaft needs to be turning when you shift it..
Pull the drive and shift it while on a stand with the back cap off.. Top cap off with mess with the proper operation of the shifting..
Make sure all the races and bearings are in place between the cap and top gear.
hope this helps..

Ball and spring appear intact and working well.

There is a + gear and a - gear.

The nuts are at the bottom as suggested.

Slight shavings on the upper vent plug, assumed normal for break-in on a new drive???

One thing that seemed odd was the shift mechanism seemed sloppy or loose. Even compared it to another good drive there seems to be a big difference, yet nothing obvious jumping out just yet.

Also, with the top cap off how "loose" should the upper bearing feel? Can be moved 1/8 to 1/4" in any direction. I assume the top cap aligns everything and this is eliminated? Seemed excessive.

Lastly how do I identify what gears are in there? This drive is supposed to be fully upgraded and everything does look new inside it, just have this shifting issue.