'96 Mercury Force Reverse Issue

[anglerslade]

Hey Guys, I'm new to the forums, but it seems you give the best advice around from what I've read. I've seen several other posts that seemed somewhat similar to my problem, but I wanted to give complete specifics and see what you think.

First of all, I have a 96' Mercury Force 120 HP Outboard. I bought the boat last year and after a couple months, the engine would die when put into reverse. Not knowing anything about boats, I took it to the shop, and I believe I was overcharged by about $500 just for them to adjust the idle. When I got the boat back, when reversing, I would hear a metallic clicking in the lower unit. I did some research and found that the shift linkage needed adjusted, which is something that should have been done after the idle was adjusted. When winterizing the boat, I adjusted the shift linkage so there was no sound in forward or reverse, and figured I was good. When I went out the first time this spring, the metallic sound in reverse was back, which I read was due to the difference of having a hose on it compared to the actual load of being in water. I didn't have tools with me and went with it anyways. I made the mistake of forgetting about it the next couple times I went out and just kept saying, "Oh I'll adjust it next time." Well, the time I made a specific trip out JUST to adjust it in water, reverse wouldn't engage at all. It just basically spins freely while making a very fast metallic clicking. It is also very hard to put it into reverse.

At first thought, I was sure I had completely worn down the clutch dog and/or the reverse gear and planned on changing them. However, I've read some things about the linkage cable and other possible things to look at, so I don't want to order any parts until I have a better idea of what I may need. If I do an lube sample and find metal in there, is it a pretty good bet that the clutch dog and reverse gear are shot?

I appreciate any advice you guys can give!!!

[EuropeanAM]

Welcome to BBC!

A good starting point would be to sample the gear lube.... AND then disconnect the shift cable at the engine.

MANUALLY move the shift linkage to see if reverse gear can be engaged.

Several different gearcases "could" be on your engine... so moving forward, it would be necessary to have:

-Engine Serial Number
-Model Number
-Pictures identifying gearcase (at least side and rear views).

[lester lewis]

My 95 120hp force did like yours it was the shift cam. it is in the lower unit. it pushes a pin that engages the clutch dog. you will need to pull the lower unite off. the piece cost less than $20.00 make sure it is not your cable out of adjustment. good luck

[anglerslade]

Thanks guys, I'll try and sample the gear lube this weekend. I looked for the Engine Serial and Model Numbers, but on the plate that would have them, it was completely worn off. Is there anywhere else I may find this information? Pictures are no problem, I'll get those this weekend when sampling the gear lube.

I checked the shift linkage, I did in at the lake, and I adjusted it all the way to a fixed nut (I assume was there to keep from going to far and hurting the forward gear?) and I was able to back out slowly, but with the metallic click still. If it was something as simple as the shift cam, that would be great.

If there are metal shavings in the gear lube, does that mean it is likely the gear/clutch dog, or is it possible it's still something cheaper like the cam?

[anglerslade]

Okay, I have some new information regarding my reverse problem. First of all, I went to my owners manual, and it had the shift cable installation guide on it. I'm a bit angry, because when I was at the ramp one day when my reverse was making all the noise, a guy that worked at a local marine repair shop came over and told me which cable was the shift cable. After reading the manual and knowing a bit more what I'm looking at, I realize he was actually pointing at the throttle cable. So, I followed the actual shift adjustment, and in reverse I found that the cable was falling about 1/4" short of being full engaged in reverse. I really hope this solves the problem and that I didn't ruin it down in the gearcase by letting it go like that for so long.

Also, I found the serial number to my engine.

Description: Force 120 ELPT
Serial #: OE194296

I adjusted the linkage so that forward and reverse were full engaged (checked with the cable off while rotating prop). While doing this, I made the following observations:

In Reverse, it would go a quarter turn clockwise, and nothing counter clockwise.
Neutral was free spin both directions.
Forward would go free clockwise, but made clicking noises, and wouldn't go counter clockwise.

Is that how it is supposed to work? If not, how should I proceed?

[EuropeanAM]

Your results are roughly accurate (depending on whether you have a 3-jaw or 6-jaw gearcase).

See how it does when you run it.... if the problem persists in EITHER gear, I would recommend that you immediately have it checked (to avoid any further damage to gears or clutch dog).

[anglerslade]

I have a 3-jaw gearcase, so I'm hoping it ends up being something fairly cheap. I decided I'm just going to bite the bullet and take it to the shop tomorrow. I hate being without a boat for a couple weeks, but it's better than making things worse. Thanks for the help! Made my decision easier, ha!

[EuropeanAM]

If they are going to be in the gearcase for ANY reason, definitely have them replace the CAM (detent).