Transmission troubles

I've got Cal 3-27. The engine is a yanmar 1gm. The transmission is a Kanzaki KM2-A. It has been struggling to shift into forward lately. My internet searching seemed to indicate that the drive cone and forward and reverse gears need to be lapped. So, I removed the transmission and took it home. I disassembled it, lapped the mating surfaces, reassembled and reinstalled the transmission. On the bench, and in the boat before starting the engine, the transmission now shifts smoothly. With the engine running however, it shifts easily into forward (this is accompanied with a sound that sounds a little like the crack of a bat), and it does not come back out of gear easily. In fact, to get it out of gear I have to push on the shifter (on the side of the transmission) with a big wrench to get it out of gear. Once again, with the engine off, it shift smooth and easily. So, why will it not shift out of gear with the engine running? Did I over-lap the drive cone? Did I over-torque the lock nuts on the output shaft? To be clear, the problem is that the drive cone is getting stuck tight to the gear. During my trouble shooting I removed the transmission while it was stuck in gear and pulled the shifter. The drive cone was stuck. Thanks for the help, Matt

The below problem illustrates why repairing transmissions is best left to the professionals. Our rebuilder will also provide a 1 year warranty. Please contact me off list for details. *Joe DeMers - owner* Sound Marine Diesel LLC SoundMarineDiesel.com <http://www.soundmarinediesel.com/>*phone & fax (860) 666-2184* On 6/2/16 11:30 AM, ya… [at] e-rohde.net [Cal_Boats] wrote: > > > I've got Cal 3-27. The engine is a yanmar 1gm. The transmission is a > Kanzaki KM2-A. It has been struggling to shift into forward lately. > My internet searching seemed to indicate that the drive cone and > forward and reverse gears need to be lapped. So, I removed the > transmission and took it home. I disassembled it, lapped the mating > surfaces, reassembled and reinstalled the transmission. > > > On the bench, and in the boat before starting the engine, the > transmission now shifts smoothly. With the engine running however, it > shifts easily into forward (this is accompanied with a sound that > sounds a little like the crack of a bat), and it does not come back > out of gear easily. In fact, to get it out of gear I have to push on > the shifter (on the side of the transmission) with a big wrench to get > it out of gear. Once again, with the engine off, it shift smooth and > easily. > > > So, why will it not shift out of gear with the engine running? Did I > over-lap the drive cone? Did I over-torque the lock nuts on the > output shaft? > > > To be clear, the problem is that the drive cone is getting stuck tight > to the gear. During my trouble shooting I removed the transmission > while it was stuck in gear and pulled the shifter. The drive cone was > stuck. > > > Thanks for the help, > > > Matt > > > > -- *Joe DeMers - owner* Sound Marine Diesel LLC SoundMarineDiesel.com <http://www.soundmarinediesel.com/>*phone & fax (860) 666-2184*

With my amateur status firmly intact I have corrected my transmission problem. With regards to the question I posted here, it was simply a matter of lubricating the shifter cable and removing play from both ends of the cables sheathing. All in, I went from a transmission that wouldn't shift into forward, to a well functioning transmission for about $30 and several hours of labor. And, I now know much more about what's inside the scary metal box.

Nicely done. There is nothing harder than taking the first step. Fred Haas 3-30 NEMESIS Tacoma On Jun 17, 2016, at 3:53 PM, ya… [at] e-rohde.net [Cal_Boats] <Ca… [at] yahoogroups.com> wrote: > With my amateur status firmly intact I have corrected my transmission problem. With regards to the question I posted here, it was simply a matter of lubricating the shifter cable and removing play from both ends of the cables sheathing. > > > All in, I went from a transmission that wouldn't shift into forward, to a well functioning transmission for about $30 and several hours of labor. And, I now know much more about what's inside the scary metal box. > >

Yes good job on that! I have had the same emotions toward certain scary parts of the boat until I get reading on it and hands on it. All of a sudden it's a strength. > On Jun 17, 2016, at 2:11 PM, Fred Haas ca… [at] gmail.com [Cal_Boats] <Ca… [at] yahoogroups.com> wrote: > > Nicely done. There is nothing harder than taking the first step. > > Fred Haas > 3-30 NEMESIS > Tacoma >> On Jun 17, 2016, at 3:53 PM, ya… [at] e-rohde.net [Cal_Boats] <Ca… [at] yahoogroups.com> wrote: >> >> With my amateur status firmly intact I have corrected my transmission problem. With regards to the question I posted here, it was simply a matter of lubricating the shifter cable and removing play from both ends of the cables sheathing. >> >> >> All in, I went from a transmission that wouldn't shift into forward, to a well functioning transmission for about $30 and several hours of labor. And, I now know much more about what's inside the scary metal box. > >