Greetings! I have 1979 Mercury 80 hp. I removed the lower unit to replace the water pump and now I have an issue with installing it back. Looks like something preventing the gear shaft on the lower unit from entering inside of the gear shaft coupler on the outboard part.
Before removing the lower unit the gear was switched to forward. Everything was done according to the manual.
It seems that the drive shaft matches the cranckshaft correctly - when I turn the flywheel clockwise, the propeller turns in the forward direction.
However, something is preventing the lower unit from going completely up to its place leaving the gap about one inch between the lower unit and the upper part.
The plastic housing for the end of the upper shift shaft and the reverse lock rod is in place.
I tried to turn the gear shaft on the lower unit with plyers a little to try to re-align it with the upper shift shaft - no success. I tried to switch gears - no difference.
Looks like the lower shaft just doesn't go inside the upper shaft (coupler) for any reason. I don't see anything that may cause this problem - everything is clean, no obstacles, and the situation is the same with a grease or without it. So, nothing should mechaincally prevent the shaft from going inside the coupler. But it does.
My only guess is that there may be a difference in the temperature causing the squeezing of the metal. My boat with the outboard is outside with about 30 degrees at nighttime and the lower unite is kept in the garage with about 40 degrees. In my opinion, it's not the huge temperature difference to cause the trouble. But maybe I'm wrong?
Did anyone have the same problem? Is there any trick to solve the issue and install the lower unit easilly? Some real-life experience not described in the manual?
I greatly appreciate your help!
Before removing the lower unit the gear was switched to forward. Everything was done according to the manual.
It seems that the drive shaft matches the cranckshaft correctly - when I turn the flywheel clockwise, the propeller turns in the forward direction.
However, something is preventing the lower unit from going completely up to its place leaving the gap about one inch between the lower unit and the upper part.
The plastic housing for the end of the upper shift shaft and the reverse lock rod is in place.
I tried to turn the gear shaft on the lower unit with plyers a little to try to re-align it with the upper shift shaft - no success. I tried to switch gears - no difference.
Looks like the lower shaft just doesn't go inside the upper shaft (coupler) for any reason. I don't see anything that may cause this problem - everything is clean, no obstacles, and the situation is the same with a grease or without it. So, nothing should mechaincally prevent the shaft from going inside the coupler. But it does.
My only guess is that there may be a difference in the temperature causing the squeezing of the metal. My boat with the outboard is outside with about 30 degrees at nighttime and the lower unite is kept in the garage with about 40 degrees. In my opinion, it's not the huge temperature difference to cause the trouble. But maybe I'm wrong?
Did anyone have the same problem? Is there any trick to solve the issue and install the lower unit easilly? Some real-life experience not described in the manual?
I greatly appreciate your help!