Engine gear control cable replacement

Alctel

.
Dec 13, 2013
264
Hunter 36 Victoria
Hi there,

On attempting to move the 1980 36' hunter I own, I discovered that the gear handle on the control column that moves the engine into forward/neutral/reverse doesn't appear to be working. Further investigation shows that the engine performs correctly if you manually move the lever on the engine, so my thoughts are a stretched/broken control cable.

Has anyone replaced this part or taken apart their steering column? Any 'gotchas'?

Its a Yacht Specialties if that helps.
 
Jun 21, 2007
2,117
Hunter Cherubini 36_80-82 Sausalito / San Francisco Bay
Actel:
I am not able to reply in any detail right now. I will have more time in a few hours to jot down some thoughts. Stand by.
 
Jan 4, 2007
406
Hunter 30 Centerport
Before you rush to replace the cable verify that the pin on the shifting cable at the engine end has not come off and that the exterior of the cable is still anchored to a fixed point before the shift lever on the engine. If they are correctly attached remove the pin from the shift lever and have someone **** the ever On the binocal. If the cable doesn't move remove the compass and see if the cAble an the cable cover are fixed in place at the lever end My First thought is that one of the attachments is loose allowing the cable or he cover to slip. You night have a broken end or a seized cable. If that the case you're at replacement
 

Alctel

.
Dec 13, 2013
264
Hunter 36 Victoria
f they are correctly attached remove the pin from the shift lever and have someone **** the ever On the binocal.
Thanks for the advice - not quite sure what this part meant though

I will check the fixed attachment point before the engine - if it's something simple like that i'll be an extremely happy bunny
 
Jun 21, 2007
2,117
Hunter Cherubini 36_80-82 Sausalito / San Francisco Bay
Hello again Alctel:

I'm up in the Sierra Nevadas on a ski trip. So I don't have access to my home computer on which I have more stuff stored on the hard drive including a pdf of the Yacht Specialties instructions. I won't be home until Thursday.

I also have a Yacht Specialities system on my 1980 Hunter 36. And I have had it completely apart.

Several situations might apply to your condition:

1) Cable has failed;
2) The locking set bolt between the cable and the lever axle has become loose;
3) The plastic housing through which the shifter axle is mounted has broken inside.

I am typing here a lot from seven years ago memory. Here is a link to several threads with more detail that might get you started about the pedestal. . Go through them. Some include pictures and drawings.

http://hunter.sailboatowners.com/index.php?option=com_wrapper&Itemid=274

Once on the page, type "specialties" in the phrase box. And "rardiH36" in the author box.

My suggestion, also per Nelsonhow, is to remove the compass from the top of the pedestal. From there you will be able to see the top of the throttle and shift cables and their attachment to the shift lever axle. As you move the lever, you will likely observe the fault.

If 1), then the attachment of the cable end fitting to the axle is secure. And nothing seems to look otherwise suspicious. Moving the lever, you will feel no engagement with the engine. Completely no feedback. The replacement cables are known as "Morse" cables. I haven't needed to replace mine (yet) so you will need to get advice from elsewhere about the part # and installation instructions. Before ordering the part I would first remove the old one just to verify that it has failed.

If 2), all looks fine except the axle slips at the cable attachment fitting. Simply tighten the hex set bolt.

If 3), then it's more of an issue. Things will rock around and look wrong as you shift the lever. In the search results of the url link I gave above, you will find more info. But in a nutshell, inside the housing, the gear and throttle lever axles go through a plastic extrusion bushing to which the Morse cable end is bolted. Many years ago, owners began to report that the old plastic became brittle and failed (completely separated) often without warning. And causing shifting to become impossible. I had read about this when I bought my boat. Upon inspection, I observed stress cracks. (The replacement housing part is no longer available, but I have read that one company does have the pattern to re-create in Aluminum.) In my case I was able to "re-manufacture" mine by encasing the offending extrusion in 1/16" SS sheet metal and then filling the housing completely solid with epoxy ... thus making it all much stronger probably than even when new. And for very few $'s. It will take me a lot of time to remember the steps and write them down. So I won't do until you come back that cracked housing plastic is the cause.

Question: Did this just fail? Was shifting OK during the survey?

regards,
rardi
 

Alctel

.
Dec 13, 2013
264
Hunter 36 Victoria
Thats a whole lot of info - thanks so much. I plan on starting on Thursday - really hoping its just something that's loose.

It worked fine during sea trials 2 weeks ago. When you move the gear lever manually, you can see the lever on the column move, but not vice-versa. Weird.
 
Jun 8, 2004
1,061
C&C Frigate 36 St. Margarets Bay, Nova Scotia
I have an H37 Cutter with an Edson pedestal, so not sure how much my advice will apply but, on my boat the shift cable has failed twice. Both times the shift cable broke where the 'fork' threads on to the cable just below the compass, inside the pedestal. Both times I was lucky that there was enough thread left on the cable to temporarily reconnect things and get on with the voyage. The root cause was that the shifter crank arm on the transmission (at the other end of the cable) had suffered corrosion and become stiff to operate. I have written about replacing the shifter cable here on the forum (you can search for it) but, again, I am not sure how much applies to your boat. I guess "Check that the transmission shifts easily by hand before installing a new cable" is my message. Good luck!
 
Nov 6, 2006
10,048
Hunter 34 Mandeville Louisiana
Alctel, Sounds like the upper cable housing clamp in the pedestal may have come loose.. There is a blow-up and some description of this cable attachment in the "Downloads" section of "boat info" Your pedestal is probably a Merriman Yacht Specialties one. the company is long gone, but the site has some good info.. If you do have to replace the cable, take pictures of how it is run, and study the upper cable clamp in the pedestal carefully before pulling the old one out.. Don't completely remove the big screw just below the wheel axle .. it holds the clamp ...which will fall into the bottom of the wheel column and be very difficult to replace ! Ya might try a quick thing.. put the transmission into neutral manually down below.. then on the pedestal , center the shift lever then try to tighten that big screw just below the wheel axle.. If that doesn't fix it, then a lot more investigation is in order.. Good Luck..
EDIT.. On top of page, click on "Boat Info" then click on "Downloads and general info" then scroll down to "Merriman Parts" and click on that..
 
Last edited:
Jan 4, 2007
406
Hunter 30 Centerport
Blame auto correction on my I phone. I'm meant the pedestal column right under the compass. If you lift the compass and the compass collar off you'll see the cable connections. I bet that the retaining clamp on the outside of the shift cable is loose. But you'll be able to see both the clamp and the end of the cable with the compass and collar off
 

Alctel

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Dec 13, 2013
264
Hunter 36 Victoria
So I got the top of the pedestal off - and discovered that the lever wasn't moving the cable - it was slipping.

This is great news - I'm hoping this means I can just tighten the nut near the lever and avoid replacing anything!
 

Alctel

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Dec 13, 2013
264
Hunter 36 Victoria
So to update - it looks like the tiny little screw that holds the lever handle onto the actual metal rod had completely given up the ghost and had had the end come off. I think the hole with have to be re-drilled, but for now it appears that putting a slightly longer screw in works. Thanks for your help everyone!

It also seems a bit odd that one tiny screw would hold the handle in place, but thats the way it goes I guess!
 
Jun 21, 2007
2,117
Hunter Cherubini 36_80-82 Sausalito / San Francisco Bay
Alctel:

Thanks for coming back with your findings. Causes me to certainly have a look on my boat for the condition of the set screws that secure the throttle and gear handles to the through-axle. I hadn't even noticed that these existed!

But also don't forget about item 3) of my previous post. The original Yacht Specialties control housing plastic is now getting on 34 years "brittle". Would be interesting to hear from other Yacht Specialties owners if they have had failures.

Being confident in engine control is a must on boats. So everything in the system on your new boat is worth some detailed integrity inspection.
 
Jan 4, 2007
406
Hunter 30 Centerport
Mine cracked. I glued it up and then exposed one layer of fiberglass cloth to the back side to strengthen it. The sanded and painted it. Should last another 20 years.
 

Alctel

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Dec 13, 2013
264
Hunter 36 Victoria
I also noticed cracking around it. I'm going to take of it once I get it to the island and haul it. I'm guessing they don't make the part anymore?
 
Dec 15, 2011
12
hunter 36 1982 cowichan bay
Hi Alctel. Checked out your blog. Cool.Hey you might want to check out Cowichan Bay by Duncan. There are a few good marinas and if your really feeling salty go on the hook in the bay. Places to park your car,groceries,boat stuff,ect... Also Sooke area, if you need to be in Vic. I guess you allready found out the cost of moorage?! YIKES. I kept my boat in cow bay up till aug then moved her to Squamish to save some $. I bet Vic is High $ now but Oak bay is beautiful and a great place to sail from. Good luck crossing and check that weather channel . I think its going to blow this weekend . Mike
 
Jun 21, 2007
2,117
Hunter Cherubini 36_80-82 Sausalito / San Francisco Bay
Alctel:

Enjoyed seeing your blog and pictures.

I've attached here a pdf of the Yacht Specialties installation instructions. Also for Edson pedestal which is similar in concept. This one has maintenance tips.

Re replacing the housing. No, it is not made anymore. From years back, I do remember some forum chatter about some shop somewhere being able to custom fabricate. An archive search might reveal the detail.

In the meantime, I found this thread which within the opening post has pictures of a housing that failed.

http://forums.hunter.sailboatowners.com/showthread.php?t=144124

rardi
 

Attachments

Jun 21, 2007
2,117
Hunter Cherubini 36_80-82 Sausalito / San Francisco Bay
Yanmar QM Series Operation Manual

Alctel:

Here is Yanmar's Operation Manual for the QM series engines. Not an end-all document, but should be of good use if you are not familiar with small diesel engines.
 

Attachments

Alctel

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Dec 13, 2013
264
Hunter 36 Victoria
Thanks guys. Regards mooring, unfortunately I have to stay close to Vic, due to my day job. Once I can persuade them to let me telecommute though, it's on!

The boat came with both the Yanmar operators manual, AND what I'm guessing the mechanics manual is (two binders full!). So I'm counting my lucky stars.

Thanks for the other two pdfs, I'm going to print them out and keep them in one place