Bravo 2 Clutch Grief

Thornton69

Well-Known Member
Sep 15, 2014
1,148
Northern BC
Boat Info
1981 245 SDC
2021 Solar 420
Engines
'97 5.7 Bravo 2
'20 Merc 25 EFI Jet
Have a 1996 B2 which developed an issue with getting locked in forward after a long cruise. Initially broke the helm cable trying to get it back to neutral. Didn't see any problems with it but replaced the lower shift cable while at it. Problem was not corrected and immediately returned after a 30 min cruise. Could also feel a slight pulse in the shift lever while trying to return to neutral. Tore into the upper and found one of the clutch springs badly warn and marks indicating it may have been caught in the bite of the shift collar. Shift fork was also damaged from fighting with it. Went to order some pieces for it and found bulletin 2001-17. Apparently Merc decided to supersede the parts in all the prior Bravo's to match the 2000 and later internals. All gears, bearings, clutch and shift assembly have to be replaced. Other than the springs and fork, these look great. Looking like I may have to spend $3000 in parts if I cant come up with the $200 worth it really needs. Never heard about this bulletin before so thought I would share it. If anyone is familiar with it, I am wondering if the springs and fork are the same if ordered for the later units?
http://mercruiserparts.com/bulletins/001/04//2001/EN_17.PDF
RWQB5998.JPG IMG_2153.JPG
 
What exactly is your problem ? Neither one of those parts look that bad. You might have another issue. Those parts can be sourced but not from merc.
 
The clutch gets locked in forward. I have ordered new thrust bearings (driven gears) and seals. Suspect the thrust bearings are allowing the gears to spread a bit too far apart (combined with the warn spring) allowing it to get pinched between the shift collar and reverse gear. Not sure but it has a small line in the wear area of the spring. Shifts perfect until up on step for a while.
 
Am going to check driven gears for up and down play with new bearings when they get hear. No signs of excessive heat in oil or housing while on step but may be a contributor as well?
 
Did you replace the clutch and rough up the gear cups? Did those bearings look like junk?
 
The clutch is not available on these older drives. It has to be replaced with the full gear set as per the bulletin. The clutch has never slipped and only shows slight wear. The wear it does have would allow for more collar travel though.
Who is the aftermarket supplier you referred to? Bam in Florida showed limited amounts of oem parts for these but not having luck with the shift fork. Will probably get it built up at a local machine shop to correct alignment with the collar.
 
Bearings and gear pattern looks great. No indication of any kind of wear in the housing.
 
If you have the part #'s of the stuff you need , you could start your search. Add a clutch to your list. Plenty of used stuff on CL and Ebay. Plenty of Marine drive shops that hoard parts for guys like you.
 
Actually spent half a day online looking. Other than one on ebay that looked like it was in a fire, was unable to find anything. The part numbers for the clutch components and assembly all refer back to the bulletin. The local shops have nothing as well. One of them have a B3 without props from 2003. Don't know if that will even bolt to the transom assembly I just rebuilt. Would love to just get a clutch and shift assembly and get back on the water.
 
2003 will bolt right on. It's a big country, somebody has the parts you need. Your looking in the wrong place if they refer to the bulletin. Your searching for NOS , right?

B3 would be a serious upgrade from that B2. All the uppers were the same,for similar years I;'m sure you know that.
 
807375A1 is the clutch for my drive. One pops up on ebay used but is in horrible shape. Mine isn't bad. Was planning to flip it all so it is used in reverse. There was a complete gear assembly as well which is the one I referred to as looked like it was in a fire. Would be nice to find something covered in dust on someone's shelf, but this problem has been out there since 2001 when parts were discontinued.
The B3 I am looking at is off a 383 and is 2.2:1. Mine is 2:1 so different gears. They wont sell it unless torn down and resealed so am sure it will be at a premium. And then of course tack on 1500 or better for the props.
 
Same clutch I have in my 99. Mine says A2 probably the same as A1. There' 4 of them on Ebay right now. 1 is new. The fork is there as well. Call merc customer support and see if A1 is the same as A2. I bet it is.
There's a zillion Bravo's out there. your not looking for the holy grail
 
I appreciate your time scoflaw. I don't know what the difference is between A1 and A2 either. Will make a call tomorrow and try to find out. Have read that some of the clutches appear identical but angles are different. Some of the part numbers are in reference to different gear ratios. As mentioned in previous posts, my clutch has never slipped and looks great. Better than the used ones on ebay. The spline on it's shaft has very little wear as well. The complete used assemblies on ebay show plenty of wear on the splines. Looked like a roll of the dice to me.
This drive has spent it's life behind a 260. Imagine there is far greater stresses put on yours with the 502 in front of it. Hopefully if you ever hit a problem with yours, there will be alternatives for you.
Were you aware of the bulletin? I wasn't and was in part, why I made the post.
 
So if the clutch and the cup on the gear look good. Replace the spring, shifter fork and a new lower cable.

Spending 3K on an old drive is something I wouldn't do. Bravo's getting stuck in forward is a common problem, the clutch gets welded to the gear cup, but this doesn't sound like your issue
 

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