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1975 9.9 Gear case reseal issues

J

jim18611865

Regular Contributor
I am trying to do a complete reseal on this 75' 9.9 15" Evinrude.
I have everything out except the shift shaft o-ring washer and bushing.
I made a slide hammer, hit it with freeze spray, strapped it to a large trailer and tried to use a ratcheting strap to pull it out.
This thing won't move.
Is there no hope of changing that o-ring?

Thanks

Jim
 
You must be kidding here.----------You use a piece of 1/4" threaded rod with a nut that is cut way down to pull it out.-------Or you run a 5/16"-NC tap in there to pull it out.--------Nutting to it at all.
 
Not kidding at all. I ruined the 1/4-20 threaded rod already.
I will be getting another one tomorrow.
I even made a puller like the one at the bottom of this page.
http://www.leeroysramblings.com/Lower_unit.htm
Stripped the threads.

I am getting to be an expert at putting that nut in there.

This was a salt water engine for the last 5-6 years.
Everything else wasn't that bad.
 
OK, I got it. More force said the horse. I used a new threaded rod and a 1/4-20 coupling instead of a nut for more thread area.
I also had to put another coupling and a nut together at the top to keep the rod from spinning.
Boy did it pop. Now I am waiting on a yoke locator (319991) instead of making one (or two or three).
I can see the value of this tool and a little harder to make.
Thanks

Jim
 
You do NOT need a tool to reinstall the yoke !!!-----------If you turn the gearcase upside down it will fall into place every time.
 
I tried your upside down way a few times, no go. I am sure that is an experience thing.
The tool came today and on the second try I got it (yoke and fwd. gear) in.

Now the issue is those F#$%&*! detent balls and spring on the prop shaft!
What is the trick to getting both in and not having them come out?

Thanks again!!

Jim
 
Thanks again, even if only moral support.
I decided to get the drive balls in this morning while my mind was fresh, not after a day at work.
It was actually easy if I studied it first.
I put the shift rod in before the manual said to.
I put one ball and spring in and set the prop shaft in all the way.
Used a screwdriver with grease to place the other ball in place. Slightly pulled out the prop shaft, compressed the ball into place, then used the shift shaft to put it in reverse getting the clutch dog to cover the balls completely.
Dropped the reverse gear in, and got the bearing carrier in place before something happened.
I think I am home free now.

Thanks again for all you guys do to help us amateurs out. It is truly appreciated!
Jim
 
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