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Author Topic: Shift Shaft broke on 1992 200HP Mercury - need advice  (Read 1001 times)

October 17, 2007, 09:28:22 PM
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jdupree

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Shift Shaft broke on 1992 200HP Mercury - need advice
« on: October 17, 2007, 09:28:22 PM »
My shift shaft on my motor broke on me last weekend.  The sleeve broke that slides over the star gear on the lower unit.  After further review, come to find that the shaft itself is stainless steel but the sleeve that goes onto the gear on the lower unit appears to be pot metal :evil:   What a sorry design :evil:

Anyway, the proper way to fix this is having to remove the powerhead :cry:   Considering that fishing season is here, that is not an option right now.  Just wanted to know if anyone has any experience welding stainless steel :?:

I have already cut the shaft in half right below the yoke where it is visible.  My plans are to get a new shaft and cut it.  Place the new shaft in the lower unit and slide it back on.  I have found a welder who claims he can weld stainless with no problem.  I plan to use a stainless steel sleeve to join the 2 ends.  

Just wanted to feedback about welding stainless steel.  Will it hold up :?:
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John L. Dupree, III
1999 Aquasport 245 Explorer - 225 Johnson Ocean Pro
AQABLA84E999
Member #257
October 18, 2007, 09:41:36 AM
Reply #1

GoneFission

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Welding
« Reply #1 on: October 18, 2007, 09:41:36 AM »
It is no problem to weld stainless - I would guess your welder will use gas/tungsten arc welding (GTAW, or tig).  If done right, the welded joint will be stronger than orginal.   :wink:

Just be careful with the dimensions and cutting - remember the old adage - measure twice, cut once - maybe even measure several times, because if you cut it wrong...   :oops:

Get it fixed, 'cuz here's what you're missing (remembered to take the camera yesterday):



See ya on the water!
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Cap'n John
1980 22-2 CCP
Mercury 200 Optimax 
ASPA0345M80I
"Gone Fission"
ClassicAquasport Member #209

October 18, 2007, 04:19:51 PM
Reply #2

Kaczki

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« Reply #2 on: October 18, 2007, 04:19:51 PM »
Personalized Shirt?  Wow! :thumright:
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1971 19-1
They don\'t build \'em like they used to.
October 18, 2007, 04:52:21 PM
Reply #3

LilRichard

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« Reply #3 on: October 18, 2007, 04:52:21 PM »
Nice redfish!

Jdupree - I do not follow what you're saying... post us an image possibly?

Is this a rotating shaft, or just a shifter?
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October 19, 2007, 08:28:47 AM
Reply #4

jdupree

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« Reply #4 on: October 19, 2007, 08:28:47 AM »
Quote from: "LilRichard"
Nice redfish!

Jdupree - I do not follow what you're saying... post us an image possibly?

Is this a rotating shaft, or just a shifter?


This is just the shift shaft.  It just rotates to the left or right only when you put it in forward/reverse.  As you can see by the picture, the shaft coming down from the powerhead is still there.  I will just cut the new shaft to length and weld both of them together with a stainless steel sleeve.  While I am at it, plan to replace the rusted yoke and the lower bushing where the motor turns.  I have some up & down play.
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John L. Dupree, III
1999 Aquasport 245 Explorer - 225 Johnson Ocean Pro
AQABLA84E999
Member #257
October 19, 2007, 08:59:57 AM
Reply #5

LilRichard

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« Reply #5 on: October 19, 2007, 08:59:57 AM »
Gotcha.  I don't see why it would not work...
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