888 Shift Shaft Nightmare

[Ted K]

Help please! Since replacing water pump 4 days ago, I can not get my gear case back on. Properly at least. When I separated the lower from the upper, the shift shaft had stuck to and came up and out or should I say, stayed with the upper half! No big deal, removed bushing and fished out washer and clip parts and installed new shift shaft, clip, washer bushing assy. and proceeded to re-install gear case. Each and every time I have followed the manual procedure to the letter (ie: shift lower in forward, hold prop shaft ccw. upper int. shaft held up and in place with rubber bands) Every thing went together as planned and when the last nut was tight (of course still have my death grip on prop shaft ccw) As soon as I let go, I test it by turning prop each way and then it spins free again! What could be wrong? I have done and re-done this at least 4 times! Tried every idea I can come up with. I'm running out of will power and summer!
(edit) I have also assured that upper has been in fwd from the get go and new lower shift shaft is in all the way and locked in fwd as well.

 

[Eric 3.7LX Alpha 1]

Re: 888 Shift Shaft Nightmare

Did you remember to re-install the stainless washer on the splined lower shift shaft before installing to the upper?

 

[Don S]

Re: 888 Shift Shaft Nightmare

When you put the upper housing on the lower, the shift shaft in the upper housing must be facing forward when the shift shaft is turned clockwise and the PROP is turned counter clockwise and goes into gear.

 

[Ted K]

Re: 888 Shift Shaft Nightmare

1) Yes, the s/s washer is in place.
2) I do not have upper removed from boat. I can only assume it is as from the beginning, the remote has been in full forward. Looking up at it from below, the cotter pin (when seated properly) is pointing straight toward the boat. Every thing feels tight and there is no rotational play in the intermediate shaft when seated and held with the rubber bands. Once together and if prop shaft is turned, it unlocks. Click click click both directions. I think I'm screwed.

 

[Ted K]

Re: 888 Shift Shaft Nightmare

Update: Got my gear case on and shift shaft aligned properly! Thanks to Bt Doktur for the tips and I found out that the answers were in plain sight! Filled it and now to the power trim. Think it needs fluid. I WILL be in the water next week!
Thanks again everyone.