Day 7 - Bermuda to Flores: autopilot stopped working at 3am

Blue Note
Marco M.
Thu 15 May 2025 16:27
Date:  Thursday 15/05/25   - Time:  12:04 Bermuda time
Position 35:26.193N 45:25.63W
COG 80T SOG 7.2kt, Wind 318T 19 kt,
Temperatures: Air 17C, Sea 20.2 C
Barometer: 1024.8  hPa - steady
Sailed distance since departure:  1068 NM
Percentage trip: 57 %
Last 24h Sailed Distance: 159 NM   
Time since departure: 7d 0h 4 m
Average Speed since departure: 6.35     kt
Average VMG since departure:   5.67      kt
Average VMG speed last 24h:     6.31      kt
Intention: sail to Flores
Distance to End on rhumb line: 719 NM
ETA : Tuesday May 20, @ 12:00

Detailed Track:
https://share.garmin.com/svBlueNote

Last night at about 3:30 am, during Andrea's watch and with a 20kts of wind and 3 meters waves, the autopilot suddenly stopped working.
After trying without success to re-engaged it we started to hand steer until daylight to then evaluate better the problem.
After breakfast and reading the manual, at 6 am (Bermuda time) we started some trouble shooting.
The simple hard-reset (turn it off then back on) did not work.
Then we empty the lazarette of several items (life-raft, grab-bag, spare life jacket, emergency tiller, buckets, several tenders)
until there was enough space to enter it to check the autopilot computer.
No fuse broken, all contact were good and when we engaged autopilot we checked the voltage at the contacts for the linear-drive actuator,
and observed voltage jumping from positive to negative.



Andrea at the helm and holding the lid of the lazarette with his foot, me inside the lazarette reaching out for voltmeter.

We then decided to put all back in lazarette and check linear drive.
That involves entering the "engine compartment" from the hatch in the cockpit.
I have done this several time when the boat at anchor or on the hard, but this was the first time doing it when under sail and
beside the difficulty of entering with lots of clothes on, once inside was relatively "calm",
With the autopilot on I could hear the electric motor turning, with no gear crunching noise.
Looking at the contacts it looked that the one for the engine drive were looking ok, but the one for the "clutch" looked flimsy.
We decide to remove the driver and inspect it inside the boat.



Andrea hand steering and me inside the boat, while Yael (beside taking photos) was handing me all required tools.


The linear drive inside the boat with cover removed to check electric motor.

The contacts from the linear drive.

The little red wire of the "clutch"  wire looks very corroded and about to fall off.
The blue one appears also to have the wire exposed and corroded where the black cover of cable stops.
It looks like when removing the cover and exposing the two little wires, the insulation cover of the two little wires were also cut,
then corrosion did his job. The autopilot was already installed when I purchased boat in 2010 and I assumed it is the original autopilot
from 1998. Therefore wires lasted 27 years.

We replaced both connectors for the "clutch" reinstalled everything and VOILA' at 10 am the autopilot was back working.
A great relief for all of us since the idea of having to hand steering for the remaining 700+ nautical miles was not very attractive.

Nairobi in her "feel safe" bed.