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Lower gear case will not come loose

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stumped123

New member
1989 3.0 Alpha One - 2008, rebuilt water pump, results fine.
Boat sat couple of years, used infrequently.
Now, cannot break loose lower gear case. All 5 nuts are off or loose, plus trim tab is off.
Tried prying at rear end, broke small piece off of upper unit. It's really tight.
Had no problem in '08.

Any suggestions?

Thanks.
 
Are you sure? 2 side nuts can be loosened but not removed, front nut ,2 nuts on under side of cavitation plate and the allen head bolt UNDER the trim tab.
 
BINGO!
Just got back home from town, checked my email, and 2 minutes later had it loose!

I had been using my notes from 08, and my Clymer manual for guidance, and at my young age (76) I did not remember that bolt, and being somewhat slow to comprehend some things, simply did not get on my knees and look under the trim tab recess. Plus, it was not mentioned in either my notes or Clymer manual.

I am so thankful to you for this information, and I am indebted to you as well.

You saved me a whole bunch of trouble. While I was in town, I stopped at Home Depot, and they had a 3 pc. set of small wrecking bars on sale for $2.98, so I picked them up, and was prepared to use if necessary.

I can return the set now, and send you the $2.98 instead! Or, buy some JB Weld or Epoxy to repair the small piece of cast aluminum broken off due to my senility.

In any event, all is well that ends well, I guess, and thank you once more.

:)
:)
 
Thanks for the link; good information.
I lucked out - impeller was like new, but sleeve appeared to have been caught on the edge of the tube, so it was not allowing all of the pump's volume to get through to the engine, just enough to keep it from blowing up, I guess.
Other minor wear, but overall, good condition.

:D:D:D
 
New development. Now, cannot get Lower Gearcase back on. Boat is in driveway, all set, except for lower gearcase.
Situation: Remote Control in Forward; Prop Shaft CCW; Lower Shift Shaft CW; Upper Shift Shaft Fore and Aft; Drive Shaft greased well; water pump tube positioned on copper tube; zinc bolt in place in lower unit. Everything seems to match up except for last inch or so, and all the wiggling I can muster will not allow further installation. I'm pretty sure it's simply because the Drive Shaft splines are not mating up with the Upper Gear, but no amount of wiggling will allow mating.

Have I missed something?
 
The plastic guide tube goes in the top of the pump body not on the copper tube. a very little swipe of grease in the top of the pump housing on the rubber insert.
Lube impeller with A/F,soapy dishwashing soap, etc. turn driveshaft once or twice.
splined shaft fully cloclwise, shifter in full fwd.prop turned ccw untill locked
raise unit to catch the front stud with a few turns
install lower shoe on splined shaft.
raise unit turning prop ccw about and inch or so.drive should pop up once aligned
install side nuts and tighten being carefull the brass shoes go together correctly
install remaining items fill with oil.
 
Hey, that's what I needed, although it has been a real tough job for me.
I ended up separating the drive from the bellhousing, taking both units into my garage, since the temps in the driveway
went up to about 100. Mated them up after a little trouble with the upper shift shaft alighment with the shift shaft gear in the lower unit. Took me a little while to figure that out, with both units laid flat on floor.
Now all I have to do is wait until I can talk one of my grandsons into coming down and lending the muscle to get it back onto the boat. Maybe Saturday.
Does anyone know of plans for a DIY dolly or jig for lifting, carrying, installing this unit. Maybe I can fabricate one from some scrap wood stock.

Again, many thanks, Bt Doctur!
 
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