Difficult gear shifting on Volvo - Any Ideas?

french829 · **Posted:** Mon May 09, 2011 7:45 am

This will be our second season with our 2005 H230. All last season, we noticed that the gear shift worked much harder than what we would consider normal (particularly difficult to get into reverse). This surprised and disappointed me as I had always heard how the Volvo's were known for their smooth shifting. I will be bringing the boat home next weekend to get ready for the season. Any ideas or suggestions for what to look for or what might be the problem? Just curious if anyone else has run into this kind of issue? Thanks!

firecadet613 · **Posted:** Mon May 09, 2011 8:15 am

You need to change the shift cable. I just did it on my 268. Apparantly it is a problem with Volvos.

This thread may help.

viewtopic.php?f=11&t=6803&hilit=shift+cable

Looks like you have a 17' cable.

http://www.fourwinns.net/partbook/showp ... 04&stop=NA &mx=1

230 Mike · **Posted:** Mon May 09, 2011 10:57 am

I believe FW made the tfxtreme cable standard on the 240 starting in 06. My original was very stiff too. I had them change it to the new one at the end of last season. Looking forward to seeing how much difference it makes.

french829 · **Posted:** Mon May 09, 2011 11:45 am

Thanks guys! I suspected it was the cable and knowing this was a problem area on the 2005's makes me hopeful this might be a relatively painless fix. Definitely made docking a pain.

Walt · **Posted:** Mon May 09, 2011 3:17 pm

Yeah, my '07 Merc was the same way. Had to be replaced first season. BTW... go ahead and have them change the drive and motor while yer at it :wink:

french829 · **Posted:** Mon May 09, 2011 3:21 pm

NICE! I'll just have them throw 2 more feet on the cockpit and add an 8.1 and I should be all set. I like your thinking! :lol:

Walt · **Posted:** Mon May 09, 2011 4:09 pm

french829 wrote:

NICE! I'll just have them throw 2 more feet on the cockpit and add an 8.1 and I should be all set. I like your thinking! :lol:

.... YUP... but, get it with matching color, and see if the Admiral notices. If she mentions anything about it, just deny it by questioning her memory "No dear, that's how it's always been..... don't you remember???"

Seriously, hope the new shift cable works out for you.

french829 · **Posted:** Mon May 09, 2011 8:17 pm

Walt wrote:

If she mentions anything about it, just deny it by questioning her memory "No dear, that's how it's always been..... don't you remember???"

This response came a little too natural. I suspect you may have used this line before. Must be good advice.

EvilZ · **Posted:** Tue May 10, 2011 8:28 am

I'm ready to replace the shift cable again on my '03. I had them put the tfxtreme on last time, and it shifted very smoothly. Where I live, they seem to have about a 5-year life. Not sure what would be considered normal.

jeepman · **Posted:** Tue May 17, 2011 8:22 pm

I took the advice posted in this thread and replaced the shift cable on my 230 last weekend. Wow, what a huge difference! I ordered the TFxtreme cable (17 foot) from Overtons for $40 and it was easy to replace. Having done this in the past on Mercruiser outdrives, I can tell you the Volvo DP is much, much easier.

A word of advice to Horizon owners: If you want to do this job, you do not need to disassemble the shifter. All you need to do is remove the entire shifter panel from the inside of the boat which for me proved to be very easy after I stared at it for a while. Underneath the shifter panel I have a 6.5" speaker and a 10" sub that appear to have been factory installed. I just removed the 6.5" speaker and used a 3/8" socket to remove the four nuts and washers that hold this panel on by sticking my whole arm through the speaker hole. The panel has four studs sticking through the backside that fit into slots milled into the fiberglass. You don't have to worry about loosing the hardware once you get the four nuts and washers off. Once the panel drops in your lap, you will only need a pair of needle nose pliers to remove the cotter pin from the shifter linkage. Note you will have to move the adjustment pin (thing with female threads that holds the business end of the shift cable) from your old cable to your new cable so don't lose it.

Removing the cable from the outdrive is even easier. Just remove the trim cover and you will have full access to the shifting mechanism. Pull the cotter pin and washer off to separate the cable from the control linkage. Next loosen the retaining bolt and plate on the starboard side of the outdrive in order to free the outside of the cable from its mount. You do not need to remove the retaining bolt; just loosen it and slide the plate underneath it toward you to release the cable. Pull the cable out from the inside of the boat and toss it in the trash after you un-thread the adjustment pin off of the drive end of the cable.

To install the new one, I removed the rubber guards from one end of the new cable and then pushed it through the guide tube into the outdrive so that it stuck out of the back of the drive. I reinstalled the rubber pieces and pulled it back into place. You will probably need three hands for this trick because someone has to push the cable into the tube built into the gimbal mount from the inside of the boat and someone else will probably have to help guide it thought the drive. Be vary careful not to touch the positive battery posts with the metal parts of the cable while you are working it through the boat! I covered mine with a towel to be extra safe.

This project was WELL worth the $40 and hour of my time. My boat now shifts as smooth as silk.

french829 · **Posted:** Tue May 17, 2011 9:38 pm

Replacing mine this week and moving the batteries to port side. I can't wait to see if it makes a difference.

EvilZ · **Posted:** Tue May 17, 2011 10:10 pm

jeepman wrote:

Be vary careful not to touch the positive battery posts with the metal parts of the cable while you are working it through the boat! I covered mine with a towel to be extra safe.

Just a thought: If you dont have rubber/plastic battery terminal covers on your battery(ies), you might want to consider it for both safety and to avoid getting ticketed as others have commented on in other posts.

Good write-up on replacing the shift cable - I'm going to take another look as I was perplexed how to detach the shifter last time.

230 Mike · **Posted:** Tue May 17, 2011 11:21 pm

+1 Jim, thanks for a terrific post on the process. That's a keeper.

jeepman · **Posted:** Wed May 18, 2011 9:13 pm

Eric, please post the results of your battery move project. I am planning this soon too in the hopes that it will level out my listing problem. For some reason this drives me crazy. Last weekend I was making family members sit on the port side to correct it. I think they are getting tired of that so I need to figure out how to fix it.

I just read the post about the ticket for not having a battery post covers and I am shocked that could possibly be true. Don't get me wrong, covering the posts of your batteries is a good idea. I just can't believe they are required by law. What's next, getting a ticket for not wearing enough suntan lotion? Statistically speaking, which is more likely to kill you?

french829 · **Posted:** Thu May 19, 2011 7:29 am

I definitely post the results. Job should be completed today and we are planning the first trip of the season on Memorial Day weekend.

www.iFourWinns.com

Difficult gear shifting on Volvo - Any Ideas?

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