OMC parts 800 / Cobra outdrive drawings * How to videos

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OMC Shift Cable Removal *400 *800 *Intermediate housing

400 or 800 shift cable removal for stern drive
years 1978 to 1985

  • OMC 400 and 800 shift cable removal from intermediate housing
  • Video how to series for installation and adjustments
  • Exploded view 800 tech drawings upper gearcase or lower unit
  • Step by stem removal pictures and tools required

See Video 400-800 adjustment
See Video 400-800 adjustment
Remove shift cable end and cotter pin
Remove shift cable end and cotter pin

By author Trish Dougherty

Disconnect positive on battery wire before removing shift cable, if loose wire on cable comes in contact with with starter or tilt solenoid terminals your $700.00 cable will have melted wires.
Mark the location of the shift arm in neutral at current location before remove shift cable end and cotter pin when working on upper gear-case.

shift cable clamp
shift cable clamp

Remove driver side shift cable clamp

Replace washer
Replace washer

Remove shift cable end and cotter pin and replace washer and cotter pin so as to avoid losing any parts.

Disconnect micro switch wire
Disconnect micro switch wire

Disconnect micro switch wire

7/16 inch open end wrench required
7/16 inch open end wrench required

One 7/16 inch open end wrench will be required.

7/16 inch socket required
7/16 inch socket required

One 7/16 inch socket and socket wrench will be required and one 1/4 inch socket.

A7

black plastic wire guide

Remove bolt, washer and nut that holds the shifter arm in place.

A8

Remove bolt completely from the arm.

nylon washer

nylon washer

Remove nylon washer

 

Remove 4 screws

Remove 4 screws

Remove 4 screws

top cover

top cover

Remove top cover

 

B8

 B8

Pull clips upward

 

Pull clip out
Pull clip out

Pull clip upward and then out

black plastic wire guide

black plastic wire guide

Remove black plastic wire guide

B6
B6
 
The following parts should be removed
The following parts should be removed

The following parts should be removed

Tools required two 1/4 inch screw drives are required
Tools required two 1/4 inch screw drives are required

Tools required to remove shift wires from pulleys are just one 1/4 inch screwdriver.

C4
 
E4

E4

Remove cable wire from pulley

E5
E5
 
wire puck

wire puck

Remove both wire pucks from housing
Remove both wire pucks from housing

Remove both wire pucks from housing

D7
D7

Push in on cable

Move cable in about half inch
Move cable in about half inch

Move cable in about half inch

With cable push in slide cotter pin in on left side hole
With cable push in slide cotter pin in on left side hole

With black shift cable push in all the way, slide cotter pin located on top left into hole.

Leave pin in untill reinstalling cable
Leave pin in untill reinstalling cable

Leave pin in untill reinstalling cable

 

Remove screwdriver from claw and housing.

Slide out shift cable
Slide out shift cable

Slide out shift cable

F2
F2
 
F3
F3
 
www.sterndrive.info has used part if required

www.sterndrive.info has used part if required

www.sterndrive.info has used part if missing or broken required.

No parts get lost this way
No parts get lost this way

No parts get lost this way

 

Take 3 minutes to install

Take 3 minutes to install

Take only 2-3 minutes to install lose parts in place.

 

Replace all parts
Replace all parts

Replace all parts and don't forget to remove your screwdriver.

Tape wires together
Tape wires together

Before removing cable from boat

  • Tape lose wires with electrical tape so they don't catch on engine compartment components
  • Spray dish detergent soap on shift cable before pulling through transom hole
  • Undue three 3/8 inch bolts on 1/4 moon lift gear so out-drive can be lifted up with out the 12 volt electric power on
  • Undue 5/16 bolt that holds shift cable bracket in place, located under intermediate housing ball gear