Sun Odyssey 30i - Gearbox removal

[JFA_67]

Hi,

I'm having some problems with my gearbox (Kanzaki KM2P). It is slipping on forward gear (probably it's the usual cone clutch problem).

Does anyone have experience dealing with its removal on a Sun Odyssey 30i. I really wish I didn't have to remove the engine...

rene460 or other Sun Odyssey 30i owners, any tip?

Thanks in advance.

[MalcolmP]

Yes those Kanzaki gearboxes are a pain. I have removed and replaced the gearbox on our 39i. You need to be patient and work slowly and plan each stage. I was able to get the gearbox out without moving the engine, but it is very tight to say the least. You need to remove all the peripherals you can find etc.

Please take lots of photos, would make a valuable Hints and Tips article.

Good Luck. Malcolm

[rene460]

Hi JFA, I was fortunate enough to have no issues with the gear box in all the time I owned the boat (around 12 years), so I have ne experience with removing the gear box.

On a sadder note, I have now sold the boat, as health issues made it feel less safe for just the two of us alone on the boat, even though we sail a lake system, so not the same adventure as ocean sailing.  I did not want to end over 50 years of sailing together with bad memories.  We have to deal with what life brings.

I am trying to remember forum topics on this subject.  I seem to remember some members having trouble with the gear shift due to stretching or slipping of the cable at the gear end.  Obviously worth checking that the cable is giving the full movement required by the shift mechanism before doing something more drastic.  But Malcolm’s experience obviously indicates that clutch troubles are not unknown.

I do hope you are able to sort it out without too much pain.

rene460

[DarknStormy]

On my 36i, 3YM30 and KMP2-1 gear, I had to cut a small bulkhead loose to make room for the gear to come out and go in. See attached images. I repaired it with a piece of AL angle material: 

[JFA_67]

Oct 6, 2023 5:21:37 GMT MalcolmP said:

Yes those Kanzaki gearboxes are a pain. I have removed and replaced the gearbox on our 39i. You need to be patient and work slowly and plan each stage. I was able to get the gearbox out without moving the engine, but it is very tight to say the least. You need to remove all the peripherals you can find etc.

Please take lots of photos, would make a valuable Hints and Tips article.

Good Luck. Malcolm

Thanks for the feedback. Yesterday I managed to do it without cutting anything (I only needed to remove the gear cable and exhaust pipe). It was like a big puzzle in reverse mode . Probably it will be a lot more difficult to insert it in place...

The next step will be with a mechanic guy that already treated a lapping of the cone/gears slots of a similar gearbox. Hope he will succeed.

Once the gearbox is ready, I will install it and plan to take more photos. For the moment I only have these:


Gearbox cable before being removed 


Exhaust pipe removed


The propeller shaft was decoupled and moved to the stern. Before doing this I polish the shaft so as not to damage the Volvo Penta seal.
The gearbox was free after unscrewing its 7 fixing screws and one nut. Luckily it was not "glued" to the damper plate.
I twisted the gearbox from bottom to top and then from right to left to make it through the small available space.



Time to smile


Ready to take it to the mechanic

[JFA_67]

Oct 6, 2023 17:11:39 GMT DarknStormy said:

On my 36i, 3YM30 and KMP2-1 gear, I had to cut a small bulkhead loose to make room for the gear to come out and go in. See attached images. I repaired it with a piece of AL angle material: 

Thanks DarknStormy. That was also my plan B... Let's see if I can insert the gearbox again without cutting anything.

[JFA_67]

Oct 6, 2023 10:15:54 GMT rene460 said:

Hi JFA, I was fortunate enough to have no issues with the gear box in all the time I owned the boat (around 12 years), so I have ne experience with removing the gear box.

On a sadder note, I have now sold the boat, as health issues made it feel less safe for just the two of us alone on the boat, even though we sail a lake system, so not the same adventure as ocean sailing.  I did not want to end over 50 years of sailing together with bad memories.  We have to deal with what life brings.

I am trying to remember forum topics on this subject.  I seem to remember some members having trouble with the gear shift due to stretching or slipping of the cable at the gear end.  Obviously worth checking that the cable is giving the full movement required by the shift mechanism before doing something more drastic.  But Malcolm’s experience obviously indicates that clutch troubles are not unknown.

I do hope you are able to sort it out without too much pain.

rene460

Thanks, Rene for your feedback.

I think you made the right decision (to keep the good memories). Anyway, I still hope to sail with you

You'll be more than welcome to visit us in our beautiful city and lagoon (check it at .

Regarding the cable and its movement, everything was okay, so the problem must really come from inside the gearbox. Fingers crossed to a successful repair.


Best regards,


Jorge

[MalcolmP]

Excellent progress Jorge!

Yes more photos please on the install. I will then put together a new Hints and Tips to help others.

Cheers Malcolm

[JFA_67]

Oct 7, 2023 11:55:58 GMT MalcolmP said:

Excellent progress Jorge!

Yes more photos please on the install. I will then put together a new Hints and Tips to help others.

Cheers Malcolm

Thank you. I just added photo captions to make the process more clear.

[rene460]

Hi Jorge, thanks for that video of your lovely city.  I don’t normally watch long videos but that one was great.  I especially liked the approach to bilingual presentation.

Well done on getting the gear box out.  Its a major step in achieving a successful fix.

It would be great to catch up if you are ever in this part of the world.

rene460