Frozen Gear Lever (1/3): replacement in a Mercury 2.5hp outboard engine
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- čas přidán 4. 08. 2021
- This is the 1st in a series of 3 movies showing how I changed the gear (shift) lever in my outboard. The gear lever had become frozen due to salt corrosion over the winter. It would not go into forward gear, completely stuck.
Having watched some other CZcams movies on a similar subject, I decide to tackle this myself.
Links to each of the series of 3 movies.
Part 1/3 • Frozen Gear Lever (1/3...
Part 2/3 • Frozen Gear Lever (2/3...
Part 3/3 • Frozen Gear Lever (3/3...
I found this CZcamsr's movies useful
Channel: / @oldguydiy
Movie: • OldGuyDIY 4HP 5HP Merc... - Jak na to + styl
Thanks for the breakdown.. bc of this video I found that I could use a butane torch on the casing under the lever shaft, squirts of penetrant on the shaft, a vice grip locked super tight on to the shaft, and a little pry bar on the lower shift linkage connection to FINALLY work it loose with no need to take the power head off THANKFULLY. Then epoxied the plastic shifter on to the shaft after working it good and loose with the vice grips..
Thanks Mike, just finished replacing the gear lever on my 3.5 mercury. Exactly the same. Took 2 days. Took forever to get the power head off, I used the hammer and a piece of wood as you suggested. I also took the lower plastic cover off so I could work the gear lever back and forth with multi-grips. (Gear lever had broken off). All back together and running now. Thanks for making the video…much appreciated. Cheers, Earl
That's great. Glad it worked out.
My shifter was stuck also. I drilled 3 holes 3/16" in the housing to the shaft where the shift leveler goes through and sprayed penetrating oil in the holes. Removed the rubber plug in the lower unit and used a pry bar to work the shifter back and forth to free up the shifter. Took about a week to do letting the penetrating oil to do its job. Did not have to take the motor apart. Also can keep the shifter lubed up with the holes I drilled. Without keeping the shift lubed up it will just freeze up again. Did not have to buy any parts.
Thank you 4 your help
HI Mike, Around 2:58 in part 1 of your video, you were mentioning your fuel switch got disconnected, same problem I'm facing today. How did you get that sorted out? There's a real access issue in that small area. Would appreciate your advice, Thanks!
Mike, you're a legend. Thank you!
I removed the 7 bolts but my power head just won't come off. Is it possible that it has to be in neutral og forward gear in order to come off? I tried tapping and shaking and pulling and WD40-ing but it won't move. Any ideas?
It is hard to get off. I think it does need to be in neutral.
I had great trouble getting the power head off using blocks of wood and a hammer. In the end I screwed long m5 bolts up into four of the seven mounting holes and tapped these with a light hammer and the power head popped off easily. The trouble now is getting the gear lever out which is seized solid. I have stripped lower unit down to just the leg and inverted this in a boiling pan of water. The shaft now rotates a couple of degrees. Thanks for the great video, Mike.
That's where I got too. Very frustrating. The shaft of the lever in my case got bent with the hammering.
Good work. but this a terrible design. I think I'll throw mine away and purchase a Honda.