help pulling 1991 5hp powerhead

[crowebar]

I'm trying to pull the powerhead on my 1991 merc 5hp. I think I've removed everything. Carb, tank, every bolt I could find inside and underneath cowl. Should the powerhead pull right off? Is there anything in the lower unit I need to release? How much evvert should I use to release it? It doesn't seem to pop right off. Am I missing something. I can include pictures.
Thanks,
DC

 

[latin monkey]

Re: help pulling 1991 5hp powerhead

it'll take a little muscle getting it to budge, there are gaskets under there and it has to come straight up to slide off the splines of the shaft. just don't use any type of pry bar on the mating surface

 

[crowebar]

Re: help pulling 1991 5hp powerhead

That is just what I needed to know.
I'll go give it some muscle.

 

[latin monkey]

Re: help pulling 1991 5hp powerhead

let us know how it works out

 

[crowebar]

Re: help pulling 1991 5hp powerhead

I think the motor is stuck to the shaft. I have got it up about 1/4 of an inch, prying it carefully with screwdrivers. I can rotate the the powerhead now to the left and right a little bit as I have the powerhead up high enough up to clear the lineup dowl pins. But that is as far as it goes. I'm thinking about spliting the case to get access to the splined shaft to get some penatrating lube on it. Does it sound like I'm doing the right thing? Any ideas?

 

[crowebar]

Re: help pulling 1991 5hp powerhead

Well I split the case...oops. Didn't realze there was a plate at the bottom that needs to be removed first. Now I'll need to get one of those too. Still can't get the powerhead off. It is stuck to the shaft good. Can I get the whole shaft out if I pull the lower unit??? Any ideas?

 

[crowebar]

Re: help pulling 1991 5hp powerhead

It just keeps getting better. I tried pulling the lower unit. No luck. I loosened up the shifting linkage clamp and pulled the two blots holding the lower unit on but it won't come off either. It is loose and will come down about 1/4 of an inch and wiggle around but that is it. The drive shaft seems to be holding everything together. I'll attach some pictures this time.

 

[latin monkey]

Re: help pulling 1991 5hp powerhead

try to get some lube in there and soak it real good. just take your time and keep at it and it will break loose eventually. keep us updated

 

[crowebar]

Re: help pulling 1991 5hp powerhead

Thanks,
I hung it upside down and sprayed wd-40 down the shaft. I'll give it a day to soak in and try again.
Thanks,
DC

 

[crowebar]

Re: help pulling 1991 5hp powerhead

Got it. I made a slide hammer, hung the motor upside down and after 15 min the shaft pulled out of the water pump and broke the water pump housing on it's way out. I then unbolted the shaft holder from the bottom of the powerhead and it came right out. However, the shaft is compleatly siezed in the shaft holder (good news, since I thought the powerhead was siezed but it is just fine). Now I have to get the driveshaft out and buy a new shaft holder or whatever it is called. I'll attach a picture. So where is the best place to find parts online for a 1991 Merc 5 horse.

 

[crowebar]

Re: help pulling 1991 5hp powerhead

I got the shaft out after heating the housing. I put the shaft in my lathe and trued up a spot that was scored by the tailshaft bushing. I resurfaced the bushing and it seems to rotate nice and free. I think I just need gaskets and a waterpump housing. Any suggestions on a good online place to get parts? Thanks,
DC