'83 35 hp lower unit questions

[MushCreek]

Usually I can find my way with the older outboards, but this is my first go at a more modern one. I'm trying to get the lower unit apart, and so far have everything but the pinion gear and front gear out. How do I remove them? Do I remove the seals and bearings above the pinion so I can move it up enough to get the front gear out?

Second question- the gear in the back of the gearcase, closest to the prop, is actually the forward gear, right? The parts list calls it the reverse gear, but on mine, it's the one that is damaged, as well as that end of the clutch dog. The PO said it was starting to jump in and out of gear, so I plan on replacing or repairing the damaged parts. If the gear in front of the pinion is in fact the reverse gear, than there's no sense in removing it.

Do you think it would work to re-machine the damaged area, and get another life out of the forward gear and clutch dog? I'm a tool maker by trade, and could easily re-machine the damged area with an EDM machine, but I wonder if the parts are only case hardened, in which case it won't last long if I re-machine it. Any thoughts?

 

[MushCreek]

Re: '83 35 hp lower unit questions

Okay- I answered two of my own questions. The rear gear is in fact reverse, although I don't understand why it is more damaged than the forward gear. I know the PO had the unit rebuilt once before- maybe they only replaced the forward gear? Unless I can re-machine them, I'll have to replace the forward gear and clutch dog, at the very least. Are there any other parts I should probably replace while I'm in there? I don't feel like taking it apart again.

And I figured out how to get the other gears out- I messed around and tilted the forward gear a bit, and the pinion dropped right out.

 

[mikesea]

Re: '83 35 hp lower unit questions

No ,closest to you removing is the reverse gear,parts list is correct,remove the shift shaft that screws into the yoke assy,if you did it already ,then shake her up,you can also remove the cradle screw on bottom of skeg. That may help you out a bit,Im assuming you already took off the waterpump and pulled the shaft out,if not ,do that too.As for machining the gears,Ive done it many times as well as others,basicaiily all you need to do is machince the worn ends off,I did it with a die grinder