Service Bulletin - Marinemechanic.com
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1. e Ifthe transom assembly is a service part or is part of CMD or other diesel power package submit the claim against the transom serial number e Ifthe cable is a service part submit the claim against the original engine serial number THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 10 11 2010 Mercury Marine AUGUST 2010 2010 11R1 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives e For packaged cables in inventory submit a P amp A claim Replace the core wire and keep the shift cable assembly in stock Old Part e Inthe United States and Canada Cut the core wire in half with wire cutters to prevent possible use by mistake and then scrap e Outside the United States and Canada Follow instructions issued by your Marine Power International office or by your distributor THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior w2. 2010 2010 Mercury Marine Page 1 11 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives Identifying Affected Shift Cables Obtained as Replacement Parts To determine whether a replacement shift cable is affected by this recall find the cable date code stamped on the barrel of the lk g a EI cable jacket on the shift bracket end of the cable Re p E ron N Date code stamp Date Codes of Cables Affected by This Recall IMPORTANT The date code range for affected cables is NB111 NF141 All affected cables have N as the first character and B F February June as the second character First Character Second Character Third and Fourth Characters Fifth Character Month Code Day of the Month Shift Number For example the following table shows how to interpret a cable that has the date code NF182 2010 18th day eng Situation The core fitting may not remain attached to the core wire If the core fitting is detached from the core wire shift control will be lost Replacement of the core wire of the intermediate shift cable should be scheduled and completed as soon as possible The boat should not be operated until the repair has been completed Correction Replace the core wire of the intermediate shift cable Follow the appropriate procedures for replacing the core wire in How to Replace the Core Wire Some cables have been corrected in prod
3. PFERCURY ewer Service Bulletin Bulletin No 2010 11R1 OEM No 2010 08R1 Circulate to MoM sales Manager Accounting service Manager Technician Parts Manager Official Recall Notification Under the U S Federal Boat Safety Act Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives Scope Worldwide Models Affected Transoms Shipped With MerCruiser Engines Engine Serial Number Transom Serial Number Alpha 1A602571 1A621587 1A194127 1A468107 NOTE Note Loose Alpha and Bravo transoms may be part of a CMD power package or other diesel powered package or may have been sold as a service replacement part Shift Cables Obtained as a Service Shift Cable Shift Cable Kit a Part Spa 865436A02 865436A03 Any replacement cable or cable kit with a box date as identified on the box before February 11 2010 or after June 23 2010 is not affected by this recall If the cable has a box date within this range the date code on the cable itself will determine whether the cable is affected by this recall THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2010 11R1 AUGUST
4. ble and submit a claim for inspection without replacement 45159 Green or blue dot on the end of the core wire indicates a corrected core wire Corrected cables have been marked on the outer housing at the engine end to signify that the inner core wire has been changed 45171 Various markings to indicate a corrected cable THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2010 11R1 AUGUST 2010 2010 Mercury Marine Page 3 11 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Aloha and Bravo Sterndrives Boat builders have been painting a silver stripe around the cable behind the brass ferrule at the engine end of the cable to signify that the inner core wire has been changed Regardless of the color used on the outer cable housing the inner core wire is identified with a green or blue paint dot on the end 45170 Dealers Mark the outer cable at the engine end as shown with a white paint line 45172 NOTE All transoms with serial numbers below the affected range listed and all individual cables with date codes earlier than February 11 2010 have good cables All transoms built after the endin
5. by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 6 11 2010 Mercury Marine AUGUST 2010 2010 11R1 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives 10 While applying light inward pressure rotate the barrel on the shift cable threads until the distance between the center of the hole in the shift cable end guide and the center of the brass barrel measures 153 mm 6 0 in a End guide b Barrel c 153 mm 6 0 in 11 Install the shift cable onto the shift plate 12 Verify shift adjustment Removal Bravo Models 1 Remove the sterndrive from the transom assembly 2 Remove the intermediate shift cable from the shift plate 3 Locate the shift cable end guide that was removed from the engine shift plate 4 Loosen both set screws 5 Pull the shift cable end guide from the shift cable a Shift cable end guide b Set screws c Control cable d Anchor 16487 6 Pull the core wire from the intermediate shift cable cavity in the bell housing Core wire end THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior
6. e will reimburse the dealer for performing this recall in accordance with the instructions outlined in the Service Bulletin Mercury Marine apologizes for any inconvenience this recall may cause you However we have taken this action to ensure that your boating experience will be enjoyable and trouble free Sincerely Mercury Marine Customer Service
7. e with safety wire Twist until tight and trim the excess safety wire with wire cutters 4 Insert the core wire into the shift cable jacket located in the bell housing shift cavity 5 Continue to push the core wire through the transom assembly until the shift slide is positioned on the shift cable tube inside the bell housing shift cavity IMPORTANT Ensure that shift slide remains in an upright position and is properly engaged with the shift shaft lever roller 6 Install the sterndrive NOTE Ifthe sterndrive is not to be installed at this time make the barrel adjustment at the time of installation 7 Pushin on the drive unit shift cable while turning the propeller shaft counterclockwise until the shaft stops To ensure that the clutch is fully engaged maintain pressure on the propeller shaft with a suitable device such as an elastic strap a Inner core wire b Propeller 45214 NOTE Clutch engagement will be in forward on right hand rotation units and reverse for left hand rotation 8 Install the shift cable end guide over the core wire shift bracket end and insert the core wire through the cable anchor IMPORTANT The core wire must be completely inserted through the anchor 9 Tighten the anchor screws securely THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed
8. ered owners within the affected serial number range will receive a letter from Mercury Marine This letter will explain the situation and request that they contact their local dealer to set up a time to have this inspection performed A copy of this letter is included with this bulletin Warranty Mercury Marine will credit the dealer for the cost of the part and the labor Submit a warranty claim through your normal warranty processing channel providing the following information as applicable 1 MerCruiser engine serial number Add the transom serial number to the claim text 2 Work order to provide proof of installation of service parts 3 Flat rate code and labor e For inspection without cable replacement e For a replacement cable installed after February 11 2010 e For engines and transoms within an affected serial number range e lf the inspection required removal of the sterndrive unit Flat Rate Code SB10 Labor 1 0 hr e If the inspection did not require remocal of the sterndrive unit Flat Rate Code SB05 Labor 0 5 hr e For inspection and replacement of a core wire e Installed in a boat with a drive Flat Rate Code SB18 Labor 1 8 hr includes 1 0 hr to remove and replace drive e Ifthe transom is not installed or the drive is not installed on the boat Flat Rate Code SB04 Labor 0 4 hrs e Ifthe cable is in the box no time is allowed e Part code 221 e Failure code 40 4 The appropriate serial number for tracking the repair
9. g serial number loose cables manufactured after the final date code or any cable that has been repaired will have a green or blue paint dot on the end of the core wire Normally Mercury requires replacement of the inner and outer shift cable assembly Because these intermediate shift cables have little or no wear it is acceptable to replace the core wire only Replacement Parts How to Replace the Core Wire IMPORTANT Refer to the appropriate sterndrive service manual for instructions on removal installation and adjustment of shift cables After replacing the core wire add the paint stripe to the engine end of the cable to enable easy identification in the future Removal Alpha Models NOTE See the appropriate MerCruiser sterndrive service manual for sterndrive removal installation and shift cable adjustment procedures THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 4 11 2010 Mercury Marine AUGUST 2010 2010 11R1 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives 1 Remove the sterndrive from the transom assembly 2 Disconnect intermediate shift cable from the s
10. hift plate loosen the end guide anchor screws and remove the end guide from the shift cable a Shiftcable end guide b Screws 2 c Cable anchor d Core wire a SS SE a F Hi Ia p oa k Th a A 45220 3 Cut the safety wire and remove the screw from the shift slide a Screw b Safety wire c Shift slide 45209 4 Remove the shift slide from the bell housing while pulling the core wire through the transom assembly a Shift slide b Core wire 5 Remove the core wire from the shift slide THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2010 11R1 AUGUST 2010 2010 Mercury Marine Page 5 11 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives Installation Alpha Models 1 Install the new core wire through the shift slide a Shift slide b Core wire 45213 2 Install the set screw into the shift slide and turn until it contacts the core wire end then back the screw out a maximum of 1 8 turn IMPORTANT The shift slide assembly must be free to rotate on the core wire 3 Using a figure eight pattern secure the screw to the shift slid
11. ritten consent of Mercury Marine 2010 11R1 AUGUST 2010 2010 Mercury Marine Page 11 11 NOTICE FOR RECALL UNDER THE U S FEDERAL BOAT SAFETY ACT Dear Mercury Marine Customer Thank you for your purchase of a new boat powered by a Mercury MerCruiser engine We appreciate your business and hope everything is performing up to your expectations As part of our commitment to superior customer satisfaction we have determined that it is necessary to replace the core wire of the intermediate shift cable to ensure the durability of your MerCruiser package It is possible that a core fitting may not remain attached to the core wire If the cable end comes loose the ability to shift the drive unit out of its current gear position forward neutral or reverse will be gone without notice to the operator Failure of the shift cable if it occurs will not cause the throttle function to fail The replacement of this core wire should be scheduled and completed at the earliest possible time Do not operate the boat until repairs have been completed What should you do Contact your Mercury MerCruiser dealer and make arrangements for the repair There will be no cost for the repair to you If you have any questions or no longer own this boat please contact Mercury MerCruiser Customer Service for assistance at 1 405 743 6566 The dealer will refer to Mercury MerCruiser Service Bulletin 2010 11 for instructions on replacing the core wire Mercury Marin
12. s after shift cable installation Includes the following components UA 91 17262A1 Core wire locating tool TEETE 91 17263 Shift cable anchor adjustment tool 2 Place the shift cable anchor adjustment tool on the end of the shift cable a Shift cable anchor adjustment tool b Stud c Hole barrel placed here d Shift cable assembly 91 17262A1 91 17262 Use to set the shift cable adjustments after shift cable installation Includes the following components UA 91 17262A1 Core wire locating tool 91 17263 Shift cable anchor adjustment tool THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2010 11R1 AUGUST 2010 2010 Mercury Marine Page 9 11 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives 3 Ensure that bell housing end of core wire is positioned tightly against the core wire locating tool a Bell housing b Core wire locating tool c Core wire a Barrel b Hole in tool No 19551 5 Follow the procedures in Service Manual 39 Bravo Sterndrives for final shift cable adjustment and sterndrive installation Owner Notification All regist
13. uction Boat builders and dealers in the United States and Canada use MercNET to determine whether the wire has already been repaired First search under the engine serial number If this recall is not listed with the engine serial number search under the transom serial number THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 2 11 2010 Mercury Marine AUGUST 2010 2010 11R1 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives Identification of corrected shift cables Cables in transoms within the affected serial number range or cables within the date codes have been repaired if they are marked with a green or blue paint dot on the cable end Corrected cables are now being marked with a green paint stripe on the barrel of the cable jacket or a stripe of green tape around the outside of the cable housing at the engine end of the cable If this green marking is present core wire replacement is not necessary Some cables did not receive the paint mark on the outer cable If the paint dot is present on the core wire end but not on the outer cable the cable is still good Add a mark to the outer ca
14. written consent of Mercury Marine 2010 11R1 AUGUST 2010 2010 Mercury Marine Page 7 11 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives Installation Bravo Models 1 Install the new core wire into the shift cable cavity in the bell housing 2 Install the control cable through the shift cable end guide 3 Allow the core wire to enter through the anchor in the shift cable end guide a Set screws b Anchor c Shift cable end guide d Core wire e Shift cable extension 4 Tighten the set screws on the anchor to secure the core wire a Setscrews b Shift cable end guide 18131 5 Pull the shift cable end guide to ensure the control cable connection is secure THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 8 11 2010 Mercury Marine AUGUST 2010 2010 11R1 Replacement of the Core Wire of the Intermediate Shift Cable on Mercury MerCruiser Alpha and Bravo Sterndrives Shift Cable Adjustment 1 Install the core wire locating tool onto the face of bell housing a Bell housing b Core wire locating tool Use to set the shift cable adjustment
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