Reconditioning the shift mechanism

Types of shift mechanisms

For the models 280, 290, 285, 285A and 290A there are 3 different types of shift mechanism. The first type was installed up to and including serial no PZ 2829528. As from serial number PZ 2829529 the second type – where the ball, spring and the locking wire were removed – was installed. There is a somewhat different dismantling and assembly sequence for each type.

The third type and the shift mechanism for models DP and SP are described on pages 68–72.

NOTE! The upper gear head does not have to be removed from the intermediate housing, nor the sterndrive from the transom shield, to replace the shift mechanism.

Shift mechanism type 1

Assembly

Oil all moving parts prior to the assembly.

3. Lubricate the sealing ring abundantly and install it with the steel edge (small clearance} facing inwards the gear housing.

5. Install the balls and the springs (1). Insert a locking wire (2) in the groove of the cover and compress the springs as indicated in the picture. Cut off and turn down the end into the cover recess. The only function of the locking wire is to hold the spring in position while the shift mechanism is being installed in the gear housing.

6. Install the spring (1), the shift shoe (2) and the O-ring (3) and coat the contact surfaces with sealing compound, Volvo Penta part no. 1161099-5 or Permatex® no. 3.

NOTE! Make sure that the sliding shoe (2) is turned to a position corresponding the one in the picture. The shift mechanism will not function if the sliding shoe is turned the opposite way. Now install the shift mechanism in the sterndrive.

Set the shift mechanism in neutral and remove all adjustment pads (3) and tighten the screw. Now the vertical shaft in the upper gear housing cannot be turned. Insert a shim at the time on the screw until it is possible to turn the shaft.

Models 290 and 290A: Add one more shim to the screw (1).

Coat the shim/shims and the screw with sealing compound, Volvo Penta part no. 1161099-5, or Permatex® no. 3 when the adjustment is done and then tighten the screw.

Shift mechanism type 2

Assembly

Oil all moving parts prior to assembly.

9.

11. Install the spring (1), the sliding shoe (2) and the O-ring (3) and coat the contact surfaces with sealing compound, Volvo Penta part no. 1161099-5, or Permatex® no. 3.

12.

NOTE! Make sure that the sliding shoe (2) is turned to a position corresponding the one in the picture. The shift mechanism will not function if the sliding shoe is turned the opposite way.

13. Set the shift mechanism in a position between forward and neutral or between reverse and neutral. The pin (1) should be positioned on one of the ‘cams’. Install the shift mechanism in the sterndrive.

Shift mechanism type 3

14. Remove all adjustment shims (1) and tighten the screws. Now it is not possible to turn the vertical shaft in the upper gear housing. Insert an adjustment shim at the time on the screw until the shaft can be turned again without any sort of resistance.

Models 290 and 290A: Add one more shim to the screw (1).

When the adjustment is done, coat the shims and the screw with sealing compound, Volvo Penta part no. 1161099-5, or Permatex® no. 3 and tighten the screw.

19. Tap the eccentric piston lightly on a wooden surface to remove the spring pin (1). Inspect the eccentric piston for scoring, distortion, or damage that may cause it to leak or bind in the housing.

20. Using a screwdriver, pry out the eccentric piston seal. Clean all surfaces and check for damage that may cause leaks. Replace parts as necessary.

Assembly, models

280, 285, 285A, 290 and 290A

Oil all moving parts prior to assembly.

21. Install a new eccentric piston seal with the steel edge facing inward, as shown. Use special tool 884793

22. Install the eccentric piston (1) in the housing. Do not damage the seal! Push in the locating pin (2). Align the hole with the housing. Lock it in place with a new spring pin (3).

24. Install the shift mechanism in the gear housing in a way that the screw (1) is displaced towards starboard.

NOTE! Make sure that the sliding shoe (2) is turned to a position as indicated in the picture. The shift mechanism will not function if the sliding shoe is turned in the opposite direction.

23. Install a new O-ring (3) and insert the spring (2) and the sliding shoe (1). Coat the contact surface with Volvo

25. Set the shift mechanism in a position between forward and neutral or between reverse and neutral. (The pin (1) shall rest on one of the ‘cams’). Install the shift mechanism in the sterndrive.

26. Remove all adjustment shims (1) and tighten the screw. Now it is no longer possible to turn the vertical shaft in the upper gear housing. Insert an adjustment shim at the time on the screw until the shaft can be turned again without any sort of resistance.

Models 290 and 290A: Add one more shim to the screw.

When the adjustment is done, coat the shims and the screw with sealing compound, Volvo Penta part no. 1161099-5, or Permatex® no. 3 and then tighten the screw.

Assembly, models SP and DP Oil all moving parts prior to assembly.

28. Install the eccentric piston (1) in the housing. Do not damage the seal! Push in the locating pin (2). Align the hole with the housing. Lock it in place with a new spring pin (3).

27. Install a new eccentric piston seal with the steel edge facing inward, as shown. Use special tool 884793

29. Install a new O-ring (3), then insert the spring (2) and shift shoe (1). Coat the contact surface with Volvo Penta part no. 1141570-0 sealant.

30. Remove the shim screw and install the assembly in the upper gear head. Make sure the long edge of the shift shoe is toward the right side of the housing as viewed from the top.

3856761

31. Do not attempt to mount the special tool 3856761 on any raised portion or raised lettering on the shift housing. The tool shall be mounted closed to the housing.

Install the special tool under the two starboard side retaining screws, as shown.

NOTE! Alternatively the special tool can be mounted on the port side, but after the gear shift rod is dismounted.

With the special tool installed, add one shim to the shimming screw (1) and install finger tight while rotating the propeller shaft by hand. If propeller shaft binds, repeat this step, adding one shim at a time, until no resistance is felt through 360° of rotation.

NOTE! Do not attempt to rotate the propeller shaft with any leverage devices (e.g., propellers or pliers). This will damage the sliding sleeve and/or the shift shoe.

After the proper amount of shims have been established add one more shim to the shimming screw. Coat the shimming screw threads with Volvo Penta sealing compound, part no. 1161099-5, and install. Tighten the shimming screw to 14–16 Nm (10–12 lb.ft.)

32. Remove the special tool and install the shift linkage.