Help needed for control unit

KREW2

KREW2

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KREW2 said:
Hi all,
I hope someone can cast a bit of light on a problem.
I started up my volvo 2002 after racing only to find I could not engage gear, because the little red button to select neutral would not come right out.
I have found a new unit here it is
http://www.volvopentashop.com/DBMarine/en-GB/Details/AccessoriesCatalog/2317?path=1532/2197/2317

My question is does anyone know if it comes apart so the spring may be replaced, instead of having to buy the whole unit.
Click to expand...

The parts catalog does not show any further breakdown,

IIRC its the red plastic bit that causes it to stick. It's just a cover on a metal button

Probably the spring is OK

Get rid of the red plastic and you'll have no more trouble.

The metal bit that's underneath gets a bit of surface rust on it but that's all.

paint it if it worries you.
 
You're lucky. It did that to me when I cast off from a pontoon in Weymouth marina in a F4 - F5 blowing me off the pontoon. I put it in gear only to find it stayed in neutral. I just had a split second to leap ashore with the stern line before I drifted into the line of boats on the other side of the channel.

I replaced mine with a Morse unit only to find as Vic has said that the red plastic cover was sticking and could have easily been removed, at least as a temporary measure. Mine was a Volvo control but may have been an earlier model than yours.
 
I checked the OP's profile and see he has a Westerly Storm

the control I know is on a Berwick so a bit older. I can only just remember that it did originally have a red plastic top to the button I know it jammed and i know its been Ok ever since it "lost" it's red top.

The lever is held by a grub screw . Once the lever is off You should be able to free the button and cut away the red plastic.
 
Thanks for the response.
I did indeed take the lever off this winter all the plastic has long since gone, some of it may even be gunged up inside the mechanism. I was hoping there may be a way to dismantle the unit, and see what the problem is.
 
A previous boat had a the Teleflex single lever control with the same red button. What seemed to happen over the years was that sun and water would just cause the red button to weaken and swell. It was this red button that would jam (and not the mechanism behind).

My local chandlery ordered a bag of ten (their minimum order) and sold me a couple..

ASAP supplies seem to have them...
606103.jpg
606103-1.jpg


Replacement button at ASAP Supplies for £2.05

or.. PM me and I'll put my spare button in the post to you!
 
As I said earlier all the red plastic has gone, what's left is a brass button. I managed to pull it out with a pair of pliers, and still the lever would not move. This makes me think it's not the button sticking that is the main cause of the problem, but something in the mechanism behind which needs sorting.
 
KREW2 said:
As I said earlier all the red plastic has gone, what's left is a brass button. I managed to pull it out with a pair of pliers, and still the lever would not move. This makes me think it's not the button sticking that is the main cause of the problem, but something in the mechanism behind which needs sorting.
Click to expand...

I reckon you are right then if it still does not work when you have pulled the button out.

You can but take it off ... you'll have to do that if you replace it and have a look to see if its psooble to get it apart. I have theory that what's been put together can be taken apart. Not always true I know and sometimes not possible to put them back together a second time :mad:
 
KREW2 said:
As I said earlier all the red plastic has gone, what's left is a brass button. I managed to pull it out with a pair of pliers, and still the lever would not move. This makes me think it's not the button sticking that is the main cause of the problem, but something in the mechanism behind which needs sorting.
Click to expand...

Mine's the same; the red plastic became swollen and I took it off leaving the brass button. I find that an occasional squirt of WD40 frees it off satisfactorily.
 
Destructive Investigation

VicS said:
I reckon you are right then if it still does not work when you have pulled the button out.

You can but take it off ... you'll have to do that if you replace it and have a look to see if its psooble to get it apart. I have theory that what's been put together can be taken apart. Not always true I know and sometimes not possible to put them back together a second time :mad:
Click to expand...

I agree with Vic. If you are on the point of buying a new control then it is time to really look at dismantling the old one. This might involve drilling out rivets etc. Once you have got it apart and fixed the problem you may or may not be able to get it back together in a way that makes it serviceable. If not buy a new one of you can you are ready for next time. olewill
 
William_H said:
I agree with Vic. If you are on the point of buying a new control then it is time to really look at dismantling the old one. This might involve drilling out rivets etc. Once you have got it apart and fixed the problem you may or may not be able to get it back together in a way that makes it serviceable. If not buy a new one of you can you are ready for next time. olewill
Click to expand...

+1
 
VicS said:
I reckon you are right then if it still does not work when you have pulled the button out.

You can but take it off ... you'll have to do that if you replace it and have a look to see if its psooble to get it apart. I have theory that what's been put together can be taken apart. Not always true I know and sometimes not possible to put them back together a second time :mad:
Click to expand...

Yes this is what I will do.
I was kinda hoping that someone on here may have already tried to do this, and give me a few pointers.
Thanks again.
 
The mechanics of these units are pretty robust so unless you have a cable strand wear/breakage problem any stiffness or movement impairment might be solved by some lubrication to the mechanism. If is only the "red button" malfunction, before any more radical surgery, remove the lever by undoing the grubscrew as already described and spray some 3 in 1 oil or similar into the area that houses the button. Press the button a few times to help free it out. The main throttle control action behind the panel will benefit from a light greasing.
 
The plunger under the red button will depress a pin fitted through the main shaft that locates in a slot in the connecting gear linking the gear and throttle actuators allowing the throttle to be applied without engaging gear .When the handle is returned to the mid position it is spring loaded to engage in the slot.
Be carefull if it starts to disengage on its own caused by the slot becoming a chamfer it will get worse with dangerous potential.
All you can do is to try to clean the gunge from the shaft if that does not work buy a new one
Volvo will sell you the mechanism on it's own but you will find the TX unit complete for less

It's a TX control and the badging is irrelevant there are two options a large plastic cover allowing the cables to be fitted first and the small cover which requires fitting the cable behind the mounting surface
TX is now part of teleflex.
 
When mine broke I fitted a Teleflex Morse SB control. For some reason that escapes me I had to change the cables as well. I don't think the Volvo cables fitted the new unit.
 
scottie said:
All you can do is to try to clean the gunge from the shaft if that does not work buy a new one
Volvo will sell you the mechanism on it's own but you will find the TX unit complete for less
Click to expand...

I took your advice, bought new can of Wd40 squashed the end of the straw attachment inserted between pin and shaft and blasted it. Loads of gunge came out, and it freed up the unit, however I don't know how good a job has been done, or how long it will last. I have done a search for the TX unit, it seems you get a new lever and control mechanism for just over a £100. Do you happen to know if the fittings are the same?
 
I had the same problem and used WD40 for a season or so,but it still kept sticking occasionally.There was an article on the Moody website where someone tried replacing the spring and wished he hadn't.I bit the bullet and took mine off.Glad I did as the insides of the mechanism had partly rusted away and it was replaced with a Teleflex one.The lever was about £120 in 2009.
 
ditchcrawler said:
I had the same problem and used WD40 for a season or so,but it still kept sticking occasionally.There was an article on the Moody website where someone tried replacing the spring and wished he hadn't.I bit the bullet and took mine off.Glad I did as the insides of the mechanism had partly rusted away and it was replaced with a Teleflex one.The lever was about £120 in 2009.
Click to expand...

Thanks for that.
The gunge that I flushed out was a dirty brown colour, suggesting the inside may be corroded. I have just been on to key parts they do a replacement mechanism for £109, not too much to pay for peace of mind.
 
KREW2 said:
I have just been on to key parts they do a replacement mechanism for £109, not too much to pay for peace of mind.
Click to expand...

That's a good price.

Mine failed in a marina. Imagine if it had failed in a combination of flat calm, fog, spring tides and Channel Islands. :eek:

If the worst comes to the worst it is possible to get the engine in gear by manually moving the lever on the side of the gearbox but if access is poor it could take a while.
 
KREW2 said:
I took your advice, bought new can of Wd40 squashed the end of the straw attachment inserted between pin and shaft and blasted it. Loads of gunge came out, and it freed up the unit, however I don't know how good a job has been done, or how long it will last. I have done a search for the TX unit, it seems you get a new lever and control mechanism for just over a £100. Do you happen to know if the fittings are the same?
Click to expand...

Check if you have the mounting frame or not it is riveted onto the mechanism and allows the control to have the cables fitted and the whole assembly posted through the hole cut in the mounting surface and the frame is screwed/bolted on it will also have a larger plastic cover plate other wise the units are the same
If you look in the on line VP accessories cataloque you will see the details.
 
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