Re: 1979 Merc 40hp...trouble removing lower unit
I have the same motor, and also had trouble removing my LU. It took a lot of persuading, but basically, sometimes the splines on the gear shift rod will get stuck where they made on the LU. Try having a buddy push the control lever into Forward, then back into neutral, then reverse. Have him do this while you pull on the LU. Also, try getting a 2x4 and a hammer and tapping on the top of the LU where it is flat. Don't hit the gearcase, just the flat part, where you would mount a hydrofoil stabilizer. My apologies for not knowing specifically what this is called. Doing this should help get it loose. I had a hell of a time getting mine off, but it eventually came off, and the splines on the gear shift rod and driveshaft were a little rusty. I cleaned them up with some WD 40 and a wire brush, and then greased them lightly.
