1961 Evinrude Starflite III shift rod bushing leaking

[Hydrodyner]

I was able to drop the lower unit on my Starflite III. After draining the milky gear oil I rigged up a pressure test unit. At very low psi I could hear hissing so I sprayed soapy water around the lower unit. I found a leak coming from the hole with a brass bushing that the shift rod passes through. Any advice sealing this leak would be appreciated.

 

[Hydrodyner]

I see in the rebuild kit it looks like there is an o-ring for the bushing. Does the o-ring go inside the bushing? Any help would be appreciated!

 

[Joe Reeves]

Yes, unfortunately you need to split the two halves of the lower unit in order to remove the shift rod, after which you can slide the rod out.

Yes, the "O" Ring sits within a groove inside of the brass bushing.

It takes a little patience but you'll be able to carefully remove the old O Ring with a pointed scribe, a wire hook, and a few chosen words.

With the same patience, and a couple rods of piano wire that has the ends well rounded so as not to damage the new "O" Ring, and some WD40 or some kind of lube.... you will eventually get that "O" Ring to sit perfectly in that slot.

Done it many times using the same words on each occasion.

 

[Hydrodyner]

Thanks for the advice. Is there no way to pop the bushing out, and put an o ring in a new bushing?