1998 Mercury 125hp ELPTO Swivel Tube Lower Yoke Problems

[badcrc]

Because the boat shop wanted $1500 to do this job, I've been tearing down my 98 Merc 125hp to replace the swivel tube bushings and hardware and it's been pretty grueling. The previous owner ran the boat in saltwater and some things are corroded like the rubber mounts for the lower yoke that the long bolts go through to the yoke. I just ordered all new rubber mounts and bolts, but the problem is one of those bolts is completely stuck inside the yoke. I've used PB blaster and pounded the heck of it and it's not budging. I can't really get a cut off wheel in there or a hacksaw, and I'd like to salvage the yoke since a new one is $108+. The other problem is the upper swivel mount nuts that attach under the powerhead are corroded and one of them is stuck and none of my wrenches seem to fit the nuts. I think it's a 17mm but I used an 11/16 on the loose one and it clearly wasn't the right size but it worked because the nut is so corroded. If I use heat it will probably melt everything and these parts aren't cheap like everything for boating. So far everything has been awkward, hard to access, and hard to loosen up. Does anyone have any tips for this?

Also related to the sockets/wrenches not fitting: there are two flanged bolts that hold on what they call the "clamp" in the diagrams. The square metal plate on either side of the driveshaft housing that clamps the rubber mounts into the housing. No socket I had fit those bolts perfectly, metric or standard. I tried three different tool sets. I ended up using a 9mm but it was slightly sloppy and the bolts were in good shape. It was very close to stripping but luckily they weren't on very tight.

 

[racerone]

Find a used midsection from a fresh area.

 

[badcrc]

No Title

Find a used midsection from a fresh area.

Ya I've been looking but nothing good that I can find. The parts I do find people want so much money for it's almost not worth getting a used worn part. I finally got that bolt out of the lower yoke and I have it all apart now. I'm pretty pissed because the bushings on the swivel pin don't seem to be an issue, that was all pretty snug. The slop seems to be from where the swivel pin spline goes into the lower yoke. The two parts I was praying I didn't have to replace, and two of the most expensive parts. I found the swivel pin assembly for $254 and the lower yoke for $60, so I'm thinking about doing it. I already have about $250 into parts. I guess that's a pretty good savings over the boat shop, minus all my hours screwing around.

I have one major problem though. One of the four bolts that hold on the upper rubber mount snapped when I was taking it out, below the surface about 1/4". I got it a couple turns and it snapped. I was hoping to get some advice from you guys on how to proceed..I can get a used exhaust plate on ebay for $150. I'm not sure who can remove that bolt professionally and how much they would charge. If I bought a used exhaust plate, does anyone know if the bolt I snapped off goes through the exhaust plate into the exhaust tube? If it does, there isn't much point in getting a used one since I'd have to drill it out anyway and re-thread the hole.

Here's some pictures , but you can't really see where the snapped bolt is. The steering arm has some rust on it but it's really solid. I didn't get a good picture of the connection end but it's not nearly as bad as a lot of motors I see. What do you guys think about this swivel pin spline and the lower yoke? The spline on the pin is so worn that the groove for the retaining clip is worn away,which is why the clip was dangling down on the speedo hose. It's all garbage right?

 

[racerone]

Saw 2 of these motors the other day likely available cheap for parts..---Fresh water area.------Your location might be a huge factor here.

 

[badcrc]

Saw 2 of these motors the other day likely available cheap for parts..---Fresh water area.------Your location might be a huge factor here.

Near Seattle. Today I'm just thinking for the $320 for new swivel pin and yoke, plus whatever it costs to remove that snapped bolt, I could be done with this nightmare.