2005 Mercury 6 hp Lower Unit won't go back in

[cabovic216]

I removed the lower unit in order to replace the impeller and seals..... it was a straightforward
venture that seemed quite easy.
1) Remove the rubber cap half way down the intermediate housing and loosen the bolt that holds the shift rod
2) Remove the two bolts holding the lower unit and 'voila'... out she came.
I replaced the impeller, housing and seals and buttoned'er up and proceeded to carefully insert
the shift shaft thru bracket as well as the main shaft. Got about 80% in and it won't go any further... seems it's hitting 'something'. I've take the lower unit out 5 times and frankly can't see what could be wrong. I've tried to guide the shift rod with a scredriver without any luck. I've tilted the lower unit every which way, no luck. Also turned the crank (after putting in neutral without the spark plug connected), no luck... turned the prop and also turned the main shaft.... no luck.
Any ideas ? or should I just keep trying ? Maybe these little engines are more sensitive than I thought, and require more coaxing to get the lower unit back in.

Any help would be greatly appreciated.... I may have to go to a local boat shop tomorrow if I don't have any luck... just that I did most of the work and they'll charge a nominal rate of 1 hr.
for a few minutes of work.
Thank you in advance

 

[carholme]

Re: 2005 Mercury 6 hp Lower Unit won't go back in

216;

PLease provide your s/n as there are two and four stroke engines.

Gerry

 

[cabovic216]

Re: 2005 Mercury 6 hp Lower Unit won't go back in

Sorry if this is a duplicate message.... 4 Stroke Short Shaft S/N 0R054146.
I just tried again for 30 mins, and same thing.... it seems like it's hitting something... but what ? As many times as I've tried, I should have gotten 'lucky' at least once... I've changed other water pumps before, and this is the hardest time I've had getting a lower unit to go back in....
Any help or ideas would be appreciated.
Tx in advance
Rds
Vic

 

[carholme]

Re: 2005 Mercury 6 hp Lower Unit won't go back in

Vic;

Here is the manual for your s/n:

http://1manual.com/Mercury manuals/Service Manual PDFs/FourStroke/857138r1/cover.pdf

You must have Adobe Acrobat reader installed to use this manual. If you scroll down to the lower part of the opening page, you will see the various engine components in red. Click on the one you want and when the first page opens, click on the "Save As" icon at the top LH corner of the page and you can save it to your computer.

Select Section 6 Lower Unit and on page 6-33 you will see the start of the Gear Housing installation.

Gerry

 

[cabovic216]

Re: 2005 Mercury 6 hp Lower Unit won't go back in

Thank you very much Gerry.... much appreciated. I almost got it... I can get the lower unit in if I take out the bracket connecting the shift rod from the engine to the shift rod in the lower unit, but for some reason, when I put the bracket in, the lower unit does not align properly. I'll give it a rest and go back at it in a while. I think I'll get it with the use of a screwdriver to pry either the shift rod or the main gear shaft.

Tx again, at least there nothing exhuberant that i was missing. I'll keep the manual for future reference.
Rds
Vic

 

[Maxz695]

Re: 2005 Mercury 6 hp Lower Unit won't go back in

If there is greese on the top of the drive shaft remove it it will create a lock and prevent you ffrom getting it all the way up. Make sure the water tube and the exhaust are aligned and that the gasket for the exhaust isn,t damaged good luck