Shift strip

[Project_Mayhem]

I have a 96 Evinrude 9.9 that I just changed the impeller on. I'm having issues getting the shift linkage connected and apparently I wasn't the first one with this issue. The linkage connector that was in the motor the first time the impeller was changed was stripped. We replaced it and all has been well for the past couple of seasons. When I pulled everything apart this week it looked like the connector bolt hole was stripped. I ordered a new connector and fine thread bolts.
Well, the brand new bolts are stripping despite my best efforts to get the connector and rod re-aligned as close as possible. The original connector had one bolt hole (the problematic one) that had been rethreaded to a course thread by a PO. I see why now. I'm half tempted to drill one of these bolt holes out and through bolt it. Has anyone else ran into this with their Johnson/Evinrude?

 

[capta]

I have a 96 Evinrude 9.9 that I just changed the impeller on. I'm having issues getting the shift linkage connected and apparently I wasn't the first one with this issue. The linkage connector that was in the motor the first time the impeller was changed was stripped. We replaced it and all has been well for the past couple of seasons. When I pulled everything apart this week it looked like the connector bolt hole was stripped. I ordered a new connector and fine thread bolts.
Well, the brand new bolts are stripping despite my best efforts to get the connector and rod re-aligned as close as possible. The original connector had one bolt hole (the problematic one) that had been rethreaded to a course thread by a PO. I see why now. I'm half tempted to drill one of these bolt holes out and through bolt it. Has anyone else ran into this with their Johnson/Evinrude?
View attachment 206368

Sounds to me someone installed the wrong lower unit at some point.

 

[Project_Mayhem]

All the parts look original. The serial pops up as a long shaft as expected. I believe the fine thread bolts strip easier than the course thread. The only other thing I can think of is the groove in the linkage that the bolt mates with is slightly mis-shapen or if the shaft isnt perfectly lined up in the connector it pushes the bolt up at the incorrect angle.

Here you can see the groove that it mates with. not the greatest design

 

[Project_Mayhem]

I found the groove was slightly mis-shapen on one side so I rotated the rod connector 180 degrees. The screw is now touching a virgin portion of the groove. It still stripped a bit but it's finally in. After a quick adjustment of the shift cable it's working properly now. Hopefully it's enough to make it through all 29 bridges on the Chicago River. That would really suck to get stuck between them