8hp leg / gear case stuck

[Skidude17]

I’m trying to remove the lower leg on a new to me 1999 8hp 8ML mercury long shaft. I removed the pin at the top of the shift shaft, and the 3 nuts that hold the leg on, and loosened the piece in the middle of the shift shaft. The leg is stuck at the front of the drive. Their seems to be white oxidation around the post. I’ve banged on the front post with the nut on with a brass bar, and pried heavily with a big screwdriver. I don’t want to do anything more aggressive for fear of breaking something. Is there something I missed disassembling that’s keeping the front stuck on?

 

[racerone]

It should at least move and come down.-----Might have to remove reverse lock on the shift rod. to get it all the way off.------Use some heat where you see the white plague.-----It is possible that the driveshaft is jammed in the crankshaft spline with rust.

 

[flyingscott]

The reverse lock has to come off.

 

[racerone]

Yes I know , but it should at least separate with reverse lock still on the rod.

 

[flyingscott]

Not if the rod was full of crap and is now jammed in to lock . Or it dropped far enough that the shift rod is out of the motor pan and is hitting it.Take 2 construction wood wedges and bang one in from each side.

 

[Skidude17]

Not if the rod was full of crap and is now jammed in to lock . Or it dropped far enough that the shift rod is out of the motor pan and is hitting it.Take 2 construction wood wedges and bang one in from each side.

The reverse lock isn’t stopping the 2 pieces from separating. I’m just keeping it on there in hopes it will help keep the leg from slamming in to the ground when they do separate. I’m not sure if the construction wedges will work since 2 screwdrivers didn’t do the trick.

 

[Skidude17]

It should at least move and come down.-----Might have to remove reverse lock on the shift rod. to get it all the way off.------Use some heat where you see the white plague.-----It is possible that the driveshaft is jammed in the crankshaft spline with rust.

I’ll try some heat tonight. Any recommendations on how to break up the rust if it’s where the driveshaft and crank spline meet? I wouldn’t know how to get to it since the leg won’t come off.

 

[racerone]

Try some heat where you see the aluminum oxide.-----It might just be jammed there.-----Small propane torch may just loosen that.

 

[Skidude17]

Try some heat where you see the aluminum oxide.-----It might just be jammed there.-----Small propane torch may just loosen that.

I tried heat, and it didn't work. I heated and tried to remove, and I heated and splashed water on it to try to break things free both to no avail. I also tried flyingscott's recommendation of using wood shims. Just like with the screwdrivers, I have, well over 1/2 inch of opening on the back side of the joints, but not a hint of movement on the front.

If it is the drive shaft and the crankshaft that are fused, will I have to remove the power head to get that free? That may be might next step unless there are any other options. I don't really want to do that, but I'm afraid that might be what I need to do.

 

[racerone]

Well ----You have to do something.----Will the powerhead come off ?-----Or run to your local friendly boat shop.----They will help.

 

[Skidude17]

Well ----You have to do something.----Will the powerhead come off ?-----Or run to your local friendly boat shop.----They will help.

I haven't tried yet. I'm looking at the manual now to make sure there isn't anything special I should do before removing.

 

[Skidude17]

I removed the power head. It took a little wiggling, but wasn’t that difficult to take off. The drive shaft / crank spline are clean, no rust. It must just be that post on the front is super stuck. I think I’m going to bring it in to a shop this week and get some guidance.

 

[Skidude17]

I took it to the local outboard shop, and they said use lots of heat. Either an acetylene torch or 2 propane torches. I tried one propane torch and a heat gun. That didn’t do it, so I bought another propane torch, and the 2 torches in conjunction did the trick.
The area I heated was the drive shaft housing around the post that was stuck indicated by the red arrow. You can see in the other pic the amount of corrosion I was dealing with.