Re: 78 merc 75 lower unit
Agreed, just stay away from REV gear, it has less of a notch to fall in and in some can be kinda spring loaded. FWR and Neutral are definate positions and work better when aligning.
I assume that you confirmed that the shaft length was the same, the shift shaft and driveshaft splines are the same, both either had a preload pin or didn't have a pin on the top of the shaft, right? Otherwise it will not fit no matter how well its aligned.
Also remember not to turn your driveshaft backwards while doing this, that impeller gets put in a certain way and trying to run it backards is not a good idea, rock your flywheel to mesh them instead.