48spl lower unit rebuild help???

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I am currently rebuilding the lower unit on my 1996 long shaft 48spl johnson. We are replacing the reverse gear, clutch dog, water pump kit, and LU seals.

The lower unit had a broken skeg and badly bent cav. plate. I found a used lower unit case that was in good shape except for a paint job that we are using.

We have the new seals on the drive shaft, prop shaft, and shift rod, and bearing carriers. We replaced the clutch dog/reverse gear, and we have the carrier/shaft/gears back in the lower unit right now. I have a couple ?

1. Is there a trick to getting the carrier on the end of the propshaft and getting the two forks on the end of the shift rod into that THEN getting the pin trought the case/forks on the shift rod?????????????

2. We did not get the prop shaft seal seated all the way it seems........it will not let the annode seat all the way on the outside of the bearing carrier. I assume we HAVE to seat the seal another 1/16".....since we will have to dissassemble the whole carrier/gears again. Is that annode needed????? (local mechanic says no)THe boat is NEVER stored in the water and only used in fresh water?

3. How do you make sure that everything is correct in the LU. We have a exploded part diagram. We are making sure that everything is where it should be. Is there anything we need to know such as tricks, or specific things to look for???? Is there any adjustment in there we need to do??

4. I looked up the shift arm adjustment. I found it needs to be 21 15/16"+-1/32. That is the correct measurment right?

thanks for all your help
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Re: 48spl lower unit rebuild help???

OK.....we got it apart and then back together. We put the shift rod to spec (21 15/16"). Then when we linked it up the shift handle(tiller motor) was a bit more toward forward than it was toward reverse(start button was catching a little). When we were testing it out it would go N-F-N fine. It did not want to go N-R-N sometimes.....If the handle was in N it still was in gear when going from R-N. How do we adjust that??? From what I have read here I have to adjust the plastic turnable part on the end of the shift handle. It must line up EXACTLY with the hole on the linkage with both parts in neutral...........BUT the plastic part on the end of the shift handle is screwed in as short as it will go and still likes about 1/4" for the holes to line up. THe shift handle has ALWAYS been a bit more toward the forward gear while it was in neutral......and reverse has never been exactly right from the start. I suspect that is part of the reason that I lost reverse in the first place......and I dont want it to happen again!!!!

thanks
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[longshot]

Re: 48spl lower unit rebuild help???

anyone???

thanks
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