1989 OMC Cobra Outdrive Upper Rebuild Questions

[Bulbash]

Last summer my cobra outdrive impeller shaft just sheared off for no particular reason. replaced an outdrive with a used one from the local scrap yard. Now I'm trying to rebuild my original one to have a spare drive. I also purchased another cobra as a part donor with a different gear ratio.
1. Is impeller shaft is pressed in to the yoke?
2. What is the best way to get an old one out?
3. Maybe it's just easier to swap gears from the donor and replace u-joint?
4. Original shims are 0.54mm, how to select new shims? Would they be the same?
5. How do these gears look to you guys, is it worth reusing them?

Thank you

 

[Bulbash]

No Title

 

[wrench 3]

The impeller shaft is pressed into the yoke shaft. Drill through the center of the shaft and attach a puller. I'd tap the hole and use a slide hammer.
Shimming procedure is at http://boatinfo.no/lib/omc/manuals/1986-1998omcmanual.html#/490 on page 491. The bearing preload is addressed on the pages preseding that.
When I blow you pictures up they get too grainy to get a good look at the condition but if there's no pitting or hairline cracks they should be OK.

 

[Bulbash]

When I blow you pictures up they get too grainy to get a good look at the condition but if there's no pitting or hairline cracks they should be OK.

Sorry for the low quality pictures, website would not allow to upload any large files. Anyways, gears just have minor marks as visible on the pictures, but no pitting or cracks, They feel smooth and not grindy. Hope they will be ok.

I do not have an access to the press nor an experience using it, would taking this part to the local transmission shop be a good idea? I guess it is somewhat similar to the car differential...

 

[Bulbash]

Also, should I replace bearings since I'm in here? They feel fine, but if they fail often maybe it is a good idea to replace them...

 

[wrench 3]

A transmission shop should be able to do the press work for you if you explain what you need done.
If the gears just have polished arias on the teeth they should be good to reuse.
New parts never hurt (except for the pocket book) but clean and inspect the bearing rollers and cups for pits, push the bearing into it's cup and rotate it by hand making sure that it turns smoothly.
If the gear lub is kept in good shape there's more problems with broken gears than bad bearings.

 

[Bulbash]

Just dropped it of in the local transmission shop, was told it shouldn't be more than 2 hours of labour and if it will going smooth he might get it done in half hour...

It is a shame that marina mechanics were saying it would be a minimum 4 to 6 hours...

 

[wrench 3]

I'd have probably gone with 2 - 2 1/2 hours.