1987 8hp Johnson lower unit problem

[Moonman]

I have an 1987 8 hp Johnson. I just changed the impeller and I cannot get the lower unit back on. I remember that I had one heck of a time getting it together about 4 years ago, when I changed it last time. I have turned the prop and the flywheel a million times and cannot get it together. I am wondering if the shift rod is not aligning. It has about a 3/4 inch flat spot milled on the end of the shaft. The lower unit seems to be in gear because when I spin the prop, the shaft turns. Do you know if there is a certain position that the shift rod should be in, when assembling? I am afraid of trying to spin the shift rod for fear of snapping something off down below.

 

[racerone]

Turn gently one way.----If there is too much resistance go the otherway !----Put a vicegrip on the rod with a light grip on a sliver of aluminum beer can so you do not mark the rod.-----Nothing will break in the lower unit.---Lower unit in nuetral and shift lever in nuetral.----No more that 1/2 turn of flywheel and it neatly slides together !!-----Make sure water tube goes into pump discharge tube.

 

[Moonman]

raceone, You are the man! I used some heavy aluminum foil instead of the beer can, but it worked. Once I got the lower unit in neutral, everything went together smoothly. Thanks a lot....you saved me a lot of grief!