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Lower unit removal on 1977 Evinrude

wrvv

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"I have a 1977 25 HP long shaf

"I have a 1977 25 HP long shaft Evinrude needing lower unit repair. I can not remove the unit as the long stud at the rear will not break free. I have tried heat, cold, WD 40, and 2 lock nuts to turn the stud. The gear case and extension move slightly at the front. The stud seems locked in all 3 components. Any suggestions. I'm afraid I will break one of the castings. Bill"
 
"Two ways of doing it, both &#

"Two ways of doing it, both 'naugty' and depending on what kind of tools You have.
1: The easiest way, cut with a metal saw 1/2" above the gear case flange through the extension and the bolt. That leaves about 1/2" of he stud left in the gearcase to use a vice-grip or similat to remove the remaining bolt without ruining the threads. The extension you put in a vice and press out the stud. (Might need a couple of tonns and some heat)
2: Same procedure, but you cut at the flange. You then need a steady machine drill to drill out the stud, in worst case install a helicoil for the new one.
Good Luck!"
 
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