2003 - 225 hp Merc Optimax Shift problems (x2)

[SeLaOffshore]

I replaced the water pump on both motors after reviewing multiple Youtube postings on the topic. None of the Youtube posts cautioned the viewer (me) about proper alignment of the shift shaft. After successfully replacing the water pumps (following the video procedures) when testing with "earmuffs" and testing gear shifting at the helm it required a really hard push, but the propeller didn't spin, forward or reverse, either motor. I suspected that the shift shaft coupling didn't properly align. So I pulled the lower unit off one of the motors. I disconnected the shift cable at the motor and independently tested the shift mechanism at the helm, which moved smoothly. But when I try to move the mechanism/linkage at the upper end of the lower unit, or from the bottom end of the shift shaft - it doesn't budge. I suspect that when I put the lower unit on, that I bent something. My (google) searches have turned up nothing that helps. I can't believe I'm the first person to ever make this mistake. Short of bringing it to a shop and waiting till the end of the offshore season to get my repaired boat back, what are my options - path forward, for me to repair the damage I caused.

 

[racerone]

Did you take the lower unit off with control in nuetral, yes or no.-------If yes did you make sure it was in nuetral when re-assembling ?

 

[SeLaOffshore]

Yes, and No. Yes, it was in neutral when I removed the lower unit. No, I didn't "make sure" it was in neutral when I put it back together because the only time I even touched the lower unit gear shaft was to place the coupler on it. No one else touched the lower unit while it was off and I didn't turn the shaft to the gear box. So I am confident it was in Neutral at removal and when I re-installed the lower unit.