Mercury Commander 3000 controls rebuild kit? - sloppy inside

[SilentJ20]

Tracking down the slop in my shift/throttle lever. My (non-classic) control stick has about 1/2-3/4 inch of slop when in gear. In dead center, the spring-ball detents hold it solid, but once out of those, the slop becomes present. I removed the control box to check things out, here's what I found:

https://photos.app.goo.gl/xSLCpwvDsKkvBD9d6

This is how much the internals can move before the stick is affected.

My shift and throttle cables move smoothly, with little significant resistance. Is there any kind of rebuild kit for these old controls? I can't find anything and it basically seems I'm out of luck until a control upgrade happens--but I want to hold off if possible as I don't mind the control style.

 

[Fun Times]

Tracking down the slop in my shift/throttle lever. My (non-classic) control stick has about 1/2-3/4 inch of slop when in gear. In dead center, the spring-ball detents hold it solid, but once out of those, the slop becomes present. I removed the control box to check things out, here's what I found:

https://photos.app.goo.gl/xSLCpwvDsKkvBD9d6

This is how much the internals can move before the stick is affected.

My shift and throttle cables move smoothly, with little significant resistance. Is there any kind of rebuild kit for these old controls? I can't find anything and it basically seems I'm out of luck until a control upgrade happens--but I want to hold off if possible as I don't mind the control style.

The following may be of some help...Being you have around an 1994 boat? Merc knew there was going to be trouble on the horizon... It's been awhile but I believe what you're seeing was the reason I must have switched out what seemed like 1000 of those units back in the mid 90's.

EN_08.PDF (mercurypartsonline.net)

Genuine Mercury Marine parts, large inventory, fast shipping. Remote Controls and Components (mercruiserparts.com)

96 13 | PDF | Manufactured Goods (scribd.com)

 

[SilentJ20]

Thanks for the info. In my case, fortunately or unfortunately, my unit does not fall under the service bulletin/recall. Mine was built a month before the effective date. My mechanism part number doesn't match.

Everything seems really solid inside, it's just a few worn parts over the (many) years. I've never noticed even a hint of binding or being unable to shift. Since posting, I'd been able to come across parts lists and diagrams like the one you linked. But in my case, every part that seems to be worn is not available, or just not even sold separate. Trying not to spend the money and energy if I don't have to, but safety is of course the top priority.

 

[hughespat57]

Before assuming the really custom plates and arms are bad did you tear it down?
The two Phillips screws have bushings under them usually, nylon or bronze.
If those are worn you may be able to track them down.

 

[hughespat57]

 

[SilentJ20]

Before assuming the really custom plates and arms are bad did you tear it down?
The two Phillips screws have bushings under them usually, nylon or bronze.
If those are worn you may be able to track them down.

View attachment 142299

I tore it down part way. Enough to learn that on mine, of the two phillips screws, only the left one has a bushing that rides in the slot. I've only found one place that has that in stock, assuming the alternate part numbers I've found are the same as mine. #24 in the following diagram you shared:

View attachment 142303

BUT, that roller bushing is a case of slop, for sure. The one on the right only has the shank of the bolt riding in the slot, and the bolt is slightly worn, so I'll see if I can replace that as well.

However, the diagrams that keep coming up when I search my controller PN (822195-c1) I don't have the #14 bushings as yours shows.

LINK

I'll do a deeper teardown of the lever assembly to find out for sure. There seem to be multiple variations of this generation of "Modular Components" control box.

 

[Fun Times]

Can't quite tell what item number 14 is in hughespat57 but if it's number 4 in your design then that NYLINER part says it's active on other sites.
74647 Bushing - Mercury Marine | Crowley Marine

Here's at least what number 24/17 looks like,
8229793 Roller - Mercury Marine | Crowley Marine

Or maybe grab the last one from ebay for either use or parts, C#: 822195-C1 Mercury Side Mount Control Box FRESHWATER | eBay

 

[SilentJ20]

I managed to find rollers on another site, bought two, just in case.

I'd thought about buying that same unit on ebay, but I'm really hesitant as it may have the same worn out parts mine does. These things are getting old--my boat turns 30 next year, haha. I may as well grab the bushing and whatever else seems like a wear item once I do a teardown of mine and verify what I have. With so many versions (I think I've seen 3 so far) of these gen one cable control boxes, I want to make sure I'm getting the right stuff.