So last Labor Day weekend my lower gears ate themselves and enough of the metals got in the upper I had to replace most of the guts in it too. After it was all back together, everything worked great except occasionally when shifting out of forward into neutral or out of reverse into neutral there was a very violent clunk that vibrated the whole boat. I spoke with the mechanic that did the upper and he did state when he put the shifter pin back in that there was a little resistance. He would have replaced it but he was putting it back together for me on Sunday morning so I could use the boat and he didn't have another shifter pin available and knew I was dying to get the boat in the water. Anyway, anyone have an issue similar to this or does anyone know enough to tell me that a slightly bent shifter pin could cause what I'm feeling? Boat is currently down in Fort Myers at Nor-Tech getting some work done and I'm going to have them look into it while it's there.

Mine clunks when coming out of gear too. It's my idle. I cleaned my IAC's and it was better for a day or two. I'm hoping that it fixed itself this winter while stored in the garage.

Did your mechanic line the +/- marks up on the gears before he put the pinion assembly in? Was the shift cable modified per the imco instructions. Without digging it out I believe just the end of the cable sheath needs to be trimmed back a little.

Thanks for the responses, and there is a possibility it could be a misalignment. But since it's only occasionally, I felt the slightly bent pin was most likely. Sometimes it moves up/down when it should and sometimes there's a slight delay giving the violent clunk...