KBW20 marine gear not engaging

[mhansen]

My Halberg Rassey 35 Ketch has a Yanmar 4JHE with a KBW20 marine gear that has recently starting having issues engaging in "forward" (reverse seems to work fine). The gear doesn't seem to "slip" in/out of gear once it is engaged (I ran it for a couple hours this past weekend with no issues once I got it in gear), the issue is actually engaging into forward.

I feel like this is a "linkage" issue but unfortunately I can't do any more troubleshooting until the weekend. My plan is to disconnect the linkage at gearbox and see if it engages with any problems from the gearbox input levers.......

Looking for insights from anyone who has had similar issues.
Mike

[TheOffice]

I have the same drivetrain. My problem is reverse. Yes check the linkage and change the oil too. It takes 30w.


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[mhansen]

I've looked through the Service Manual and it indicates Dexron ATF for the KBW20 and 21; who told you 30SAE oil??

Mike

[a64pilot]

My KBW20 behind my 4-JHE takes ATF

What is the problem, hard to engage, pops out?
It's my understanding that we have clutch packs and not cones, but I have not been inside of mine to see what exactly is there.
Stated capacity of mine is 1.2L, but I have only been able to get just under a quart out on oil change

[TheOffice]

I'll check the plate on mine. Went with my mechanic's recommendation, but I just found the manual on-line and it does say ATF.

[a64pilot]

My plate is on the upper backside of the bell housing, I had to take a photo of it with my cell phone to see it



Gotta watch those mechanics

[topmast]

If the control cable is starting to fail at the gear end it may be bending and it's pull/pusheness is compromised .Disengage and operate by hand at the gear lever to isolate the problem. Oil change and filter screen clean is just part of maintenance But cables don't last forever either.

[a64pilot]

There is a filter screen?
Where, so I can remove and clean please.

[mhansen]

Update: I've pulled the Morse single level shifter and cleaned the (nearly solid) grease, then re-greased it, disconnected the shift cable at the transmission and shifted using the lever itself. Same indications, very slow to engage forward, but works fine in reverse. After some more research (thanks Google) I am leaning toward cone glazing as a "more" likely issue.

I need to hire a little rubber armed dude to wrap himself around the back of the engine and pull the gearbox now.....

More to follow, but if anyone has run into the "glazed cone" issue I'd appreciate your insights.

Mike

[a64pilot]

I am pretty sure that our KBW 20 gearboxes do not have cones, but have clutch packs although I have never been into one.
I tried to google KBW 20 exploded diagram, got the space station, a carburetor, some kind of cylinder head and a drill of some type, but no tranny.
It's my understanding that they have wet clutch packs similar to a motorcycle and that it is usually the thrust washers that wear first.
If it were me I'd certainly pull it myself, but send it off to be overhauled, often these things require tools and experience we don't have. I don't think them complex, but gear lash and somethings need to be shimmed correctly.

Now that my mind is working I think they may actually be a Hurth gearbox?
Anyway I think they have a very good reputation, but are particular about having clean fluid, I just change mine each oil change

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[mhansen]

Yup, that's what I was leaning toward; pulling it myself then sending off for rebuild. I agree, that without the proper tools (like many jobs) it could not only add a ridiculous amount of time but I risk breaking something.

We have a Yanmar dealer here in Pensacola that I'm sure would be happy to take my money.... I mean overhaul the trans.
Mike

[topmast]

May be exceptions but usually ATF means clutching disks and SAE 30 means cones or just gears. Anti foaming additives and detergent are different. Just my left handed rule of thumbs here.

[a64pilot]

Somebody posted a link to a transmission shop on another thread, Maybe east coast transmissions or something like that?
Myself I'd much rather send it to someone that specializes in that kind of work as opposed to the local guy

[mhansen]

So, I've about given up on trying our local boatyard (a Yanmar dealer / repair site) due to their "availability" so I'm probably going to have to pull it myself and ship. East Coast Marine Transmissions looks to be in NJ, has anyone heard of a similar repair site in the SE (FL perhaps)??
Mike

[TheOffice]

I found a used one and am selling my old one as core. $750 plus shipping. 2:17 gearbox.