82 Barefoot Nautique problems

[figjam_sa]

Hi Guys, I'm from South Africa and I've come here in desperate need of expert help. First of all, I'm no mechanic, so we've taken the boat to a few guys and it seems that most problems have been sorted, a few still remain.

In 2005 we bought a 82 Barefoot Nautique with a Chev 454 Big Block motor. Battery went flat first time out, alternator was replaced, after that distributor gave problems, replaced that. Then oil leaks.... After a while the mechanics found out the oil cooler was for a different model engine and too small, so they replaced that with bigger one. Now as far as I know these boats did come out with the big block v8, but if I look at the floor and some of the problems it seems that it's possible that the previous owners did replace the engine somewhere along the line and then back again - I don't know.....

Now the last couple of years the main problems is the following... After a while if I put it in Neutral, it still moves forward slowly. And when we tow a tube/wakeboarder for a while its like a clutch that's slipping. Last year we took it to a new mechanic and he said it could be the gearbox, so he sent it to a specialist that found nothing wrong with it. This year same problems again, but I saw that the gearbox oil was white so that would probably mean water in it, right.. Took it back to them, waterpump was faulty and water leaked into the gearbox and seized the clutch plates. Replaced water pump and clutch plates.

Took it out again few months ago and same story, clutch slipping after about 5min and neutral is still moving forward slowly. In the mean time the boat shop got a new mechanic and I took it back again, he drained all the oil and checked the linkages and cleaned the oil cooler and he suggested maybe the problem is with the oil, checked the service manual and they suggest a different oil. We use ATF oil.. but he replaced it with ATF again as he couldnt get anything else here (city is 3hours away). So yesterday we tested it again. Rode for about 10mins, no clutch slipping, but after a little while the Neutral problem is there again, after you let it cool for a min or two, it's better again.

Now I've read of some similar problems before and in the end it was the oil cooler of the transmission.... Well they checked the transmission last year....

Could it be that it's just the oil that is the problem or does someone have any insight of what the problem might be?

Please guys

Thanks

[Laptom]

These transmission are worn out some times and will stay engaged when in neutral.

As for the slippage, is the oil level measured when hot (boat used for some times)? you cannot measure the oil level when the transmission is cool.

[Zach@n3]

Sounds like you have a whole lot of people who don't know what they are doing working on your boat. If they didn't replace the transmission cooler after they found water in the transmission fluid then its likely still getting in there causing it to slip when hot. The staying in gear is caused by warped clutch plates. They make contact with the clutches and slightly turn the driveline because of that slight contact. If you want more help you might try posting this topic over on Correctcraftfan.com. That website is more the speed of the type of boat you have. You need to find someone around you or close that specializes in Borg Warner 1:1 transmissions. If they answer the phone and you mention that name and they don't know what it is you need to look elsewhere.

[TRBenj]

Sounds like you have a whole lot of people who don't know what they are doing working on your boat. If they didn't replace the transmission cooler after they found water in the transmission fluid then its likely still getting in there causing it to slip when hot. The staying in gear is caused by warped clutch plates. They make contact with the clutches and slightly turn the driveline because of that slight contact. If you want more help you might try posting this topic over on Correctcraftfan.com. That website is more the speed of the type of boat you have. You need to find someone around you or close that specializes in Borg Warner 1:1 transmissions. If they answer the phone and you mention that name and they don't know what it is you need to look elsewhere.

I couldnt have said it better myself.

[figjam_sa]

Thanks for the replies. Well it's got new clutch plates now.... Just a question from a noob here - does the boat work with a torque converter? If so, could it be the problem?

[Zach@n3]

Nope its a direct drive. It's either in gear or out of gear. The input shaft in the transmission spins at all times running the pump. The gear selector just redirects pressure to put the transmission in reverse or forwards. If the rebuilder didn't set up the clearances properly you have already fried all of the new parts. That's why many chose to have what seems to be a simple transmission rebuilt by a reputable shop. It takes someone with experience to do a Borg Warner properly.

[figjam_sa]

Ok.. I'll see what I can do and I'll ask on correctcraftfan as well. So just to clear the oil theory up - You don't think the oil is the problem? So I can use ATF oil?

[figjam_sa]

Update: Took it to someone that knows the Borg Warner gearboxes. These are the findings....


"I have stripped your gearbox and report as follows. The forward and reverse clutches are new and in good condition and appear to have been recently replaced. However the hydraulic pump will need to be replaced and there is some wear on the main shaft. The output shaft splines and the output shaft coupling have badly damaged splines.I suspect this is as a result of the gearbox seizing at some stage. I will get prices and availability for the spares and advise."


Followed by:


"Here are the prices for the spares needed for your gearbox.I have not included freight.We can either ship them or air freight.Please advise


Spares to repair USD 1962.80 (about ZAR 21000 )
Labour to remove ,strip,reassemble and test ZAR 4800
Remanufactured gearbox USD 2249 ( about ZAR 24000 )
New Gearbox USD 2772 ( about ZAR 30000)
I would suggest you purchase a remanufactured gearbox.
Please advise so I can get quotes on air and sea freight.
All the above prices EXCLUDE VAT"


ZAR is converted to our currency..... I then asked whether there is an alternative and if someone can machine the splines and couplings because this sounds like a **** of a lot of money. His reply:


"There are other gearboxes available but it will mean modifications to the bell housing and shaft coupling.I am not sure that it will
be any cheaper in the long run.


To be able to get your vessel working properly so you can use it without hassles we will require all the spares. Somebody got hold of the gearbox with what looks like a hammer. The gearbox has at some time seized and this has damaged the outshaft splines and the internal splines on the coupling. I suggested you get the remanufactured gearbox as this will save you the labour costs to repair your gearbox"




I am not familiar with what the prices of these parts cost in the USA so I honestly don't know if this is a load of BS. The guy works for a reputable shop in the city and seems to know what he's talking about. But is it really going to cost that much to fix my boat? Are there any alternatives??


Once again, thank you for your help!!