1999 200hp Johnson / remove upper drive shaft

[melliott56]

I am trying to keep upper drive shaft from my existing lower unit for a rebuild. How do I remove upper drive shaft from lower drive shaft in the lower unit? Am I amble to separate the two or do they come out as one with removal of pinion nut from lower drive shaft? I prefer to separate the two without taking lower drive shaft from lower unit. Ideas, hints, etc. ALL would be appreciated.

 

[racerone]

Remove the bearing housing on top of the lower unit and the upper driveshaft " falls out "

 

[melliott56]

Does the bearing housing pull out? I don't see how it is retained in the lower unit.

 

[Boobie]

Depending on the year, the upper d/s is held in by a clip type holder to the lower d/s. You need a special OMC puller to pop it out. With out this puller you'll have to pull the d/s complete out of the g/c. Removing the bearing hsg doesn't let the upper d/s fall out.

 

[melliott56]

The bearing housing is off and the upper drive shaft does not fall out! Guess I'm looking for the tool to pull this clip out which isn't readily visible. Thanks for the feedback. Any additional thoughts?

 

[daselbee]

You can get it out by pulling using the tool, OR....here is where it gets a bit sticky...you can yank it out "slide hammer style".
If I want the upper driveshaft, and I do not care about the clip, I will clamp a large vise grip on the upper driveshaft, about 3-4 inches from the top, where the driveshaft tapers down just below the splines. Clamp it in the reduced diameter area to avoid any damage to the machined upper 3-4 inches of the shaft.
I then get a BIG HAMMER, and whack the vise grip hard. It will bend the retaining clip, and pull the driveshaft out. It might take a few whacks, depending on how hard you hit it.
You can continue to use both the gearcase and the driveshaft, but the driveshaft will not be held in by that clip anymore.

You cannot get to the clip without disassembling the gearcase, in particular, removing the DS pinion gear.

 

[melliott56]

Success, a few hard whacks and I was able to get it out. A few scars in metal from vise grips but able to wet sand them smooth. Should be no issue with new lower unit when installed. Gearcase was unusable anyway so I'm not upset. Thanks for the help!