1984 CAL35 Transmission Removal

Hello: The old Hurst transmission (HBW150-2R) started howling in gear and I fear it is time for a rebuild/replacement. Question: Can the transmission be removed with the boat in the water? Anything I might need to be concerned about? Engine is a Universal Diesel 5432. Dan Harmony 1984 CAL35

Hi Dan, Yes, it can be removed while the boat is in the water. I have done it many times with different engine/trans combo and boats. 1-Prepare the work area, remove any extra parts and cover the cabin sole so it won't be damaged. Spray connection fasteners that are to be removed, like trans output shaft coupling to prop shaft coupling bolts, shifter cable connectors, etc. 2-Disconnect all electrical wiring, stating at the battery ground post. Label all wires. 3-Discon the water lines, assure thruhull valves are closed 4-Often the most difficult part is removing the bolts that hold the trans coupling to the prop shaft coupling. Reaching over and/or beside the engine to access them is difficult. Then they are likely to be seized. Keep spraying a penetrating oil like PB Blaster, tapping lightly with a hammer and wrenching again. 5-It is usually easier to remove the screws,(usually lag bolts) connecting the engine mount to the stringers and slide the engine forward on plywood or other boards, so as to not damage the trim and sole. 6-Now get ready for more penetrating oil, tapping and wrenching. After you have all the bolts out, try to slide the trans back away from the engine. This is the next major challenge as the trans input shaft may be rusted into the flex plate. If you can pull it back enough to access the bolts holding the flex plate to the flywheel. I have had to cut a hole in the trans bell housing so I could wrench the flex plate off the flywheel. Most of the time you will need a new flex plate and engine mounts. 7- I stopped rebuilding HBW's ten years ago as parts are very expensive and plus labor you may as well get a new one. As Dr. Diesel from Foley in Maine says," Thems about a dollar an hour transmission, they last about 1500 hours and they cost about $1,500."Well costs have risen, as List price is about $2,500 to $3,500 depending. The flex plate is about $173 List. 8-If room permits, upgrade to a Borg Warner Velvet Drive hydraulic trans. I rebuilt mine in 1987, it has 3,600 hours and it is still working perfectly. I've rarely heard of a Hurth, ZF or Kanzaki lasting that long Clean the splined shaft on the new trans and apply Anti-seize. On the output shaft to prop shaft apply "Loc-tite" or similar. Feel free to contact me. I can't remember if the Cal 35 has a Vee drive? If it does it will be easier. Tom Vandiver, Cal 46 at to… [at] bshmarine.com From: "'Dan Dunmire' df… [at] optonline.net [Cal_Boats]" <Ca… [at] yahoogroups.com> To: ca… [at] yahoogroups.com Sent: Sunday, July 23, 2017 9:33 PM Subject: [Cal_Boats] 1984 CAL35 Transmission Removal Hello:The old Hurst transmission (HBW150-2R) started howling in gear and I fear it is time for a rebuild/replacement. Question: Can the transmission be removed with the boat in the water? Anything I might need to be concerned about? Engine is a Universal Diesel 5432. 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Thank you Tom for the advice- spot on! The job took me about 8 hours (including a short check it out cruise around the harbor) with the most difficult part being sliding the prop shaft through the stuffing box. Did not need to move the engine up or forward. The boat does not have a Vee drive but great access both sides through the cockpit lockers. The front seal on the transmish was gone along with the fluid and bearing. The input shaft had quite a lot of rattle! Thanks also to Hale Marine in Virginia for parts and help. Dan Dunmire From: Tom Vandiver [mailto:bs… [at] yahoo.com] Sent: Monday, July 24, 2017 6:45 AM To: Ca… [at] yahoogroups.com; Dan Dunmire Subject: Re: [Cal_Boats] 1984 CAL35 Transmission Removal Hi Dan, Yes, it can be removed while the boat is in the water. I have done it many times with different engine/trans combo and boats. 1-Prepare the work area, remove any extra parts and cover the cabin sole so it won't be damaged. Spray connection fasteners that are to be removed, like trans output shaft coupling to prop shaft coupling bolts, shifter cable connectors, etc. 2-Disconnect all electrical wiring, stating at the battery ground post. Label all wires. 3-Discon the water lines, assure thruhull valves are closed 4-Often the most difficult part is removing the bolts that hold the trans coupling to the prop shaft coupling. Reaching over and/or beside the engine to access them is difficult. Then they are likely to be seized. Keep spraying a penetrating oil like PB Blaster, tapping lightly with a hammer and wrenching again. 5-It is usually easier to remove the screws,(usually lag bolts) connecting the engine mount to the stringers and slide the engine forward on plywood or other boards, so as to not damage the trim and sole. 6-Now get ready for more penetrating oil, tapping and wrenching. After you have all the bolts out, try to slide the trans back away from the engine. This is the next major challenge as the trans input shaft may be rusted into the flex plate. If you can pull it back enough to access the bolts holding the flex plate to the flywheel. I have had to cut a hole in the trans bell housing so I could wrench the flex plate off the flywheel. Most of the time you will need a new flex plate and engine mounts. 7- I stopped rebuilding HBW's ten years ago as parts are very expensive and plus labor you may as well get a new one. As Dr. Diesel from Foley in Maine says," Thems about a dollar an hour transmission, they last about 1500 hours and they cost about $1,500." Well costs have risen, as List price is about $2,500 to $3,500 depending. The flex plate is about $173 List. 8-If room permits, upgrade to a Borg Warner Velvet Drive hydraulic trans. I rebuilt mine in 1987, it has 3,600 hours and it is still working perfectly. I've rarely heard of a Hurth, ZF or Kanzaki lasting that long Clean the splined shaft on the new trans and apply Anti-seize. On the output shaft to prop shaft apply "Loc-tite" or similar. Feel free to contact me. I can't remember if the Cal 35 has a Vee drive? If it does it will be easier. Tom Vandiver, Cal 46 at to… [at] bshmarine.com _____ From: "'Dan Dunmire' df… [at] optonline.net [Cal_Boats]" <Ca… [at] yahoogroups.com> To: ca… [at] yahoogroups.com Sent: Sunday, July 23, 2017 9:33 PM Subject: [Cal_Boats] 1984 CAL35 Transmission Removal Hello: The old Hurst transmission (HBW150-2R) started howling in gear and I fear it is time for a rebuild/replacement. Question: Can the transmission be removed with the boat in the water? Anything I might need to be concerned about? Engine is a Universal Diesel 5432. Dan Harmony 1984 CAL35