Harsh and noisy gear engagement on Volvo Penta D1-30 / 130S saildrive

[gadisac]

Hello everyone,
I'm looking for some advice regarding an issue on my 2006 Bavaria 37 Cruiser.
The boat is equipped with:
Volvo Penta D1-30 (approximately 2,600 engine hours)
Volvo Penta 130S saildrive
Autoprop feathering propeller
Whenever I engage the gear, both forward and reverse, the engagement is very harsh, loud and abrupt. Instead of a smooth engagement, it feels like the transmission slams into gear with a noticeable bang.
The engine idle speed is set according to the Volvo Penta specifications, so I don't believe the idle RPM is the cause.
The gearbox works normally once the gear is engaged, and there are no obvious issues while motoring. The problem is only during the initial engagement.
It also seems that the problem has gradually become worse over time, rather than appearing suddenly.
Has anyone experienced something similar?
Could this be related to:
the saildrive transmission or cone clutch?
the gear shift cable or its adjustment?
wear inside the 130S saildrive?
the Autoprop?
something else?
Any suggestions on what to check first or common causes would be greatly appreciated.
Thank you!

[elias]

Hi , dumper disc ? Has ever been changed ?

[sunshine]

Checked the oil level? Can be really hard to get just right.  Also, should be checked with the dipstick sat in but not screwed in.  Adding a little oil might get you a smoother change. 

If yo overfill, use your oil change pump to suck some back out

[Yngmar]

Misalignment between throttle lever and clutch arm on the saildrive or sticking control cable? To test, disconnect control cable at the gearbox and use the clutch arm directly.

Wrong type of oil filled?

Otherwise probably clutch cone wear/damage.

[gadisac]

Thank you. I bought the boat in 2024, so I don't know whether the previous owner ever replaced the damper disc. I'll ask him!

Hi , dumper disc ? Has ever been changed ?

[gadisac]

I checked the saildrive oil level. I'm using the original Volvo Penta oil, and the level is correct. Even if the oil level is correct, could adding a little more still make a difference?

Checked the oil level? Can be really hard to get just right.  Also, should be checked with the dipstick sat in but not screwed in.  Adding a little oil might get you a smoother change. 

If yo overfill, use your oil change pump to suck some back out

[gadisac]

Thank you. I'll do that test by disconnecting the control cable and operating the clutch arm directly.

The oil is the original Volvo Penta oil. In January 2025, when I changed the saildrive oil, I had the old oil analyzed, and the results showed no signs of any problems.

Misalignment between throttle lever and clutch arm on the saildrive or sticking control cable? To test, disconnect control cable at the gearbox and use the clutch arm directly.

Wrong type of oil filled?

Otherwise probably clutch cone wear/damage.