clutch dog slipping?

[jxb9723]

2006 225 pro XS serial 1b243228. Torque master lower unit. Very occasinally maybe 1 out of 5 trips when steadily cruising barely on plane in the 2800-3300 range (where the prop is at its break over point due to speed/trim angle/ and rpm) I get a thud like feeling in the steering wheel from what I think is the lower unit. Cant really hear it just feel it. It never does it during normal bass fishing acceleration, deceleration, and top end. Changed lower unit fluid in search of water or metal particles. Found None.

[EuropeanAM]

Have the shift cable and control checked for WEAR or excessive free travel (shouldn't be more than approximately 3/8" free travel).

Have SHIFT ADJUSTMENT checked and verified.

There are also internal/gearcase possibilities:

-Worn bellcrank or shift spool
-Worn clutch-dog and/or forward gear

[jxb9723]

Would replacing the powerhead gasket and the water pump cause a shifting miss alignment? My dealer performed all the work this spring. I took the cover off and inspected the shifting mechanism. There was about 1/4 inch of free play in the cable and the nut was centered on the nuetral arrow. Equal amount of play on each side of the nuetral arrow. I'm leaning towards maybe I have some type of wear in the gear case like you had pointed out.

[EuropeanAM]

Possibly... although that type of misalignment will usually cause a compete inability to achieve one, or both gear engagements.

There is a METAL relay arm that runs from the cable attachment point, and connects to the shift shaft up under the intake.

While having someone turn the prop for you, shift into forward. Inspect the LEFT SIDE, LOWER COWLING for signs that this arm has been "rubbing" the inside fo the lower cowling. If so, the arm MAY be BENT (this often occurs from attempting to shift when the engine is not running.... NEVER shift unless engine is running, or prop is spinning).

[jxb9723]

Update. The only issue ive found is when the shift control is in the nuetral position. There are two stops that keep the contol from moving. When shifting back to nuetral sometimes the control stops dead center and has play in both directions. Other times it stops slighly forward with no play. I have to jiggle the shifter to get dead center. This makes about 1/16 inch difference under the cowl where the adjustments are. Under dead center circumstances adjustments are perfect under the cowl. If the shifter stops slightly forward adjustments are off 1/16 inch.

[EuropeanAM]

This situation is likely going to require some "hands-on expertise" (preferably with a Certified or Master Technician... that's well versed in the controls, cables, adjustments, and gearcase used on your rig).

It "sounds" like you may have a control problem.