Lower unit issue.

Took the new Jon boat yesterday powered by the 56 Johnson 10hp that I have been working on the last 2 months. All went well with the motor with one exception. Any time I opened past half throttle, the lower unit popped out of gear. Same for forward or reverse. I didn't encounter this in the test drum. Any ideas what might be causing this?

Thanks for the info, Pappy. The prop is brand new, so I suspect it is probably the latter. Oh well, I was planning on rebuilding the lower unit this winter anyway.

"once repaired and adjusted it should be able to be handed down to your grand kids".

Exactly what I had in mind with this project, Pappy. Given the respect she's due, I can see the old gal still going at 100 years old.

Pappy said:

Why not!
I have a 100 and a 105 year old Evinrude in my fleet that are still running.

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Have you posted photos of these? I'd like to see them!

I have attached below a photo of the reverse and forward gears and the clutch dog removed from my motor lower unit. I'm seeing some damage on the clutch dog ears (red arrows), a lesser amount of wear/tear on the gear ears (yellow arrow) and some pitting on the gear teeth (green arrow). The damage seems to be isolated to the leading edges of the ears in both the dog and the gears. From a rookies perspective, it appears that the shift yoke is not pushing the dog fully into the gears to seat it against the thrust washers and fully engage the ears. Could this be a shift linkage issue?

Thanks, Pappy. You mentioned earlier in this thread that you had posted a number of posts detailing how to adjust this style of shift arrangement but I can't seem to find any with search. Would you happen to remember the title of any of the posts?

macawman said:

Thanks, Pappy. You mentioned earlier in this thread that you had posted a number of posts detailing how to adjust this style of shift arrangement but I can't seem to find any with search. Would you happen to remember the title of any of the posts?

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I'm not Pappy ... but do an advanced search on his name and "contact" and you'll get posts of his like this:

https://www.forum.tinboats.net/viewtopic.php?f=4&t=45442&hilit=contact

Thanks for the response, Dale.

Really appreciate the link, Pappy. Exactly what I was looking for and not finding in the service manual. One question though. You make mention of a slot in the adjustment bracket behind the shift handle. Mine has 2 holes like the picture below rather than a slot. The slot makes perfect sense, but I'm not sure what I'm suppose to do with the holes.