Originally Posted by Magnum
Mark, many thanks for your response unfortunately I couldn't find anything attached to your post and have searched marine parts
without success, plenty of diagrams but not for the 120SE. Regards Doug
I thought I would post Marks excellent response to my original cry for help, just to help others who may experience similar issues:
On 25 Oct 2013, at 22:55, Mark wrote:
Attached is the schematic showing the sliding sleeve (item #22). If this is your problem, it can be accessed from within the boat without removing the drive.
Disassembly of the upper gear
unit is achieved by removing the shift dog, then taking the oil
fill cap off and depressing a large retaining lock washer on the shaft using a home made "prong tool". You will need to make this tool by using a piece 1"X4"x 1/4" steel
and welding three "fingers" coming out of it in the center that push down onto the top lock washer. On the ends of the steel piece put two bolts that screw down into two of the bolt holes of the cover. When you tighten down on these bolts, you put pressure on the lock washer and push it down.
Once the washer is pushed down about 1/2" two retaining clips are removed from a groove in the shaft. Then the whole case cover with bearing and drive gear
can be lifted off the shaft exposing the clutch
You may run into a problem where the retaining washer bottoms out on a bearing that sits below it before traveling the necessary 1/2" to remove the retaining clips. Volvo
intends you to remove the transmission
and put it in a press to remove this retaining washer. By doing so you are supporting the shaft from below.
If when pushing down on the washer the whole shaft goes down, not just the washer, then you will need to temporarily weld a 7/16" threaded stud to the top of the shaft and make a tool to pushed down on the washer while pulling up on the shaft. Afterwards, just cut the stud off and grind it flush (more or less).
This all sounds difficult, but it is easier than hauling the boat, removing the drive and disassembling it completely.