1995 Force 120hp Lower Unit installation problem

[greg219]

I have rebuild the power head for my 1995 force 120 hp outboard. Once i try to install the lower unit, there seems to be a 1.5 inch gap between the exhaust hosing and lower gear unit. I have tried moving everything around to try to get the lower unit installed properly but still have that gap. I have read similar problems with other outboards but wondering if anyone ran into something similar?


FYI- I dont know if this will affect anything but I have purchased the crankshaft which seems the same as the original but im not sure of the year. could this be causing the problem??


Thanks!

 

[HAV2FISH]

Re: 1995 Force 120hp Lower Unit installation problem

If i understand your question right, you cant get the lower unit all the way installed. If this is correct it sounds like the splines on the shaft are not lining up in the motor. If this is the case just have someone rotate the motor by hand while you are lifting the lower unit into place.

 

[pnwboat]

Re: 1995 Force 120hp Lower Unit installation problem

If you still can't get the lower unit to go into place by rotating the motor, count the number of splines inside the end of the crankshaft and the number of splines on the end of the shaft on the lower unit. There should be 15 on each. There are some crankshafts that only have 13 splines.

 

[Rope Goat]

Re: 1995 Force 120hp Lower Unit installation problem

Hi there-
I have a '92 120hp that I just had the exact same problem with. I had water leaking into my lower unit oil so before I winerized the motor and stored it, I pulled it and had it re-built in the "slow" time for the local boat mechanic.
New water pump, seals, etc. As good as new.

Long story short, as this was the 3rd or 4th time I'd pulled the lower unit, I thought it would be a breeze to get it back on....WRONG!!!!
After many feeble attempts to get it on, with the wife turning the crank by hand it just would get to within 1 to 1 1/2 inches.
After just about pulling all my hair out I finally realized that the white plastic fitting that's on the top of the water pump from the OLD water pump had gotten disconnected and was still stuck up inside the lower unit cavity.
I quick tug, it was out ans Voila, the unit fit in like a glove.
Hope that's your problem, if not GOOD luck.
I just about popped a coronary!!