ST 4000 Repair

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pierview
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Joined: 9/27/09
Posts: 552
ST 4000 Repair

My auto helm stopped "steering"> It seems it's the clutch assembly not the wiring and control signals.

I looked at various YouTube videos on repairing it and it seems fairly straight forward except there seems to be a difference between the "gray" colored unit and the "black"... I have the black. 

I also Googled the clutch repair kits available from various sources and none seem to look like the parts shown in the on-line repair videos.

So, has anyone done this; how difficult is it; any suggestions on the repair kit I need and where to get it?

Thanks for any suggestions!
 

Chuck Parker
HelenRita 2072 Mk II
2002 Tall Rig - Winged Keel
Atlantic Highlands, NJ

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Haro
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Posts: 364

Chuck, I repaired mine that is black. Some of the wheels had broken off in the disc. I put 6/32 screws through them with a nut on the inside of all the wheels to strengthen them. I also replaced the belt. You can view images and read about the repair on my website listed on my signature below.
What is it that is broken on yours? Please provide photos.

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sidthekid
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Joined: 6/1/16
Posts: 38

Hi Chuck,

I replaced my belt and clutch on a gray version in 2019. Once I got past picking up the ball bearings from the wheel assembly it was smooth sailing...

I ordered a replacement belt online and clutch kit from a company called Wave Inn, using a platform named TradeInn.com. I think the company was in the UK.

There is a ST 4000 service manual, which might be useful if you don't have it. I've tried to upload to this post.

Good luck.

Bill L

Bill & Barb
s/v Northern Lights
2002 Catalina 36 MKII #2086
Rock Hall, MD
Northern Chesapeake

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pierview
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Joined: 9/27/09
Posts: 552

Bill.... thanks for the manual.

Haro, I can't tell what's broken.  I haven't opened it up.... all I can see is the clutch lever flops down at about a 90 degree angle from vertical if taken out of the closed, set, position.

Looking at videos it seems the black version has a series of wheels around the inside of the casing while the gray version does not.. I thought the black version wheels would have "teeth" but from the video, it does not.

I'm going to have to do a little more on-line searching before I start pulling everything apart. The bad news is that it happened while we were away for a couple of weeks and had to hand steer all the time (after the first day). The good news is that when we do afternoon sails we rarely use the auto helm so I can take my time and pull it apart over the winter.

Thanks for your help!
 

Chuck Parker
HelenRita 2072 Mk II
2002 Tall Rig - Winged Keel
Atlantic Highlands, NJ

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Catboat Willy
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Joined: 12/22/14
Posts: 385

Chuck; I wish I had know about this earlier as I just left Rumson for Florida.  Anyway, I rebuilt mine and received parts from a guy up in the Vancouver Canada area. He's got all the gears and parts you'll need. Check out;  i3dgear.com or better yet, here is his  address. 
On the web at ; I3Dgear.com or you can call him in Vancouver, BC area at 250-537-8951
Belts can be obtained from Polybelt, 26 West 1st. Street Clifton, NJ 
Any rate,All the parts you'll need are still available. There are a few good YouTube videos on rebuilding the systems as well.
Bill
Bill

Bill Dolan 1990 Catalina C-36 MKI - Hull #1041  'Williwaw'
Std. Rig, Walk Through, Wing Keel
M35, Oberdorfer Conversion,
Home Waters; Charlotte  Harbor & The Gulf Islands of Florida
'You are never out of work if you own a boat'

 

pierview
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Joined: 9/27/09
Posts: 552

Thanks to all for the advice and Bill, thanks for the link to the owner's manual. 
 
In checking that, I found that there is actually an adjustment for the clutch (who knew...I used to tell my son, who is now 47,"when all else fails, read the directions"... I should have done that first). Has anyone tried that before I start pulling stuff apart? I tried to release the hex screw (which is very small.. 2mm) as per the directions but started to strip the fitting so I am currently soaking it before I try again. Can't figure out why it wont release, it's only been in that position for 20 years.

Chuck Parker
HelenRita 2072 Mk II
2002 Tall Rig - Winged Keel
Atlantic Highlands, NJ

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alfricke
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Joined: 4/14/09
Posts: 80

I went through a ST 3000 andl ST 4000, repairing them until they could no longer be repaired. I finally sucked it up and installed the Raymarine EV 200 below deck with the wireless remote. Huge difference, probably the best upgrade I ever made. I single hand most of the time and cruise Jubilee pretty hard, often in big winds (San Francisco Bay, ocean etc.) My advice is to start a savings account/slush fund dedicated to an eventual upgrade!

Al Fricke
S/V Jubilee San Francisco Bay
Catalina 36' MkII  #1867
Universal 35-B

pierview
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Posts: 552

Update on ST 4000 repair. 

I opened it up and found the belt was shredded so I replaced that and the wheels on which the two parts rotate. It seems to track OK now but the clutch lever, when in the "non-engaged" position, flops loosely to the  right. When I engage the clutch, it kind of "clunks" into position.

Any suggestions on why this happens and what to do?

Thanks!

Chuck Parker
HelenRita 2072 Mk II
2002 Tall Rig - Winged Keel
Atlantic Highlands, NJ

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sidthekid
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Joined: 6/1/16
Posts: 38

Hi Chuck,

Our clutch is also somewhat flimsy. I gently lift up the clutch arm to engage. I gently push the clutch arm to port and let it fall down to release, and the arm is basically loose in the down position. If the clutch engages AND fully releases your steering wheel, seems like it is working as expected.

In the past, our clutch would not fully release and the steering wheel would be heavy to turn since the auto pilot is basically still engaged. I have had to tighten the screw in the autopilot arm frequently in the past to keep it working.

Overall, the unit has been ok this year for light duty, but the upgrade discussed above should be considered for heavy use and robust conditions.

Bill & Barb
s/v Northern Lights
2002 Catalina 36 MKII #2086
Rock Hall, MD
Northern Chesapeake

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