Shift Rod
 

Guys , I worked all weekend with the Shift rod issue , I am replacing the V6 gearcase see previous notes , I am now replacing it with a lower unit from a 1978 140v4 , Bolts up fine problem with the shift rod off the v6 gear case its over 22 inches in N , If I connect it to the shifter I can't shift into Forward , Reverse is fine the rod approx 1 inch 2 long,
Question is do I need to buy a new 1987 v4 140 shift rod or the shift rod from the large gearcase should work ?

The rod from the V-6 should work. Sounds to me like you have the shift rod threaded in to deep, and it is bottoming and preventing it from fully engaging forward. Thread the rod all the way in until it stops with it in neutral. Then thread it out roughly 2 full turns. Measure from the mating surface to the center of the shift rod bolt hole that connects to the shift linkage. You should have 21 15/16" of distance center of bolt hole to the mating surface. Sounds like your measuring to the top of the rod and so you would be about 2-3 turns to far in.

Another method that I have used in a pinch with virtually no tools available to me is to thread the shift rod all the way in and push downward on the shift rod into forward gear. Thread the shift rod out until you feel it go all the way down and the shift rod isn't bottoming out. Turn the rod outward until the bend faces forward and install it. This isn't the best method, but will work in a pinch.

Shift Rod
 

No Sir , no matter what I do it's just about 1/4 of an inch two long , I am going to re-tread the end of it and cut it , Stay tune :)

Are you measuring to the top of the rod, or to the center of the bolt hole? Don't go cutting it just yet, the V4 and V6 loopers use the same rods. Try threading the rod out 2 turns and see if you have forward. If your measuring to the toip of the rod, you should have 22 3/16" of length from the mating base, not the rod base. There is a 1/4" of distance from the center to the top of the rod. Also try a different tape measure as a 1/4" off in a tape measure isn't much, and this measurement MUST BE EXACT!

NO NO CUTTING STOP it is same rod as Ferm said you need to just adjust it. it should not be all the way in tight.

Update
 

If I place the rod I am trying to use (From V6 Gearcase) next to the rod from the 1978 unit it is approx 3/4 of inch more . I am confuse was it not suppose to be the same ? As for the not cutting the rod when the lower unit is bolted up and shifted in the Forward gear the connector on the end is exactly 3/4 of inch higher and will not allow me to connect it . So my thinking is the damm rod needs to be cut ! Here is what I am thinking is the unit I am removing a v6 gearcase or a v8 gearcase ? Remember I can bet on the 1979 foot I am trying to bolt up because it came from a engine with the serial numbers etc. The unit I am removing who knows maybe from a car at this point..

It is highly unlikely you have a V8 lower unit. They are massive to handle the torque that the V8 has. You can't compare the old cross-flow rod to the looper rod, COMPLETELY different shift mehanisms. Your saying reverse works tells me that the shift rod is close. Try the method pushing down on the rod and threading it out until you don't feel the shift rod bottoming out. Then mount it back up. I would say 2-3 turns out will put you close to where you need to be at. If the rod is threaded all the way in, it CANNOT go into forward. Trust me on this one. If you thread it all the way in, only neutral and reverse will engage.

Unthread the shift rod all the way, then thread it back in 3 turns. Now push the rod down until it goes into forward(you may have to spin the propshaft to make sure it goes in). Now thread the rod inward until you feel it begin to bottom out. As soon as you feel it touch the bottom while threading in, rotate it out until the bend faces forward and add 1 more turn out. Try it like that and see if it works. You cannot use the old rod as a reference of how the newq one should be.

do this show us where you are measuring and what you get. this is the only measurment on a Looper you need.

I just went out and measured a shift rod that I have in the shop. It is off of an 86 140 looper, but is for a 25" shaft. So figuring you have a 20" leg, the shift rod for yours should measure roughly 30 7/8" - 30 15/16" from the very bottom to the very top. Use a yard stick or something fairly accurate for all of these measurements. But if you have the rod threaded in all the way, then you are stuck in neutral, and the rod will stick up to high to hook up with the selector in forward.

not 30" Ferm the measurment i gave above is straight out of the OMC Shop Manual. your 25" isn't 30" the shift rod in a 25" motor is only 26 15/16 "in length installed.