Brand New Outdrive ... won't go together

[zul]

I've watched many of the videos and tried all the obvious troubleshooting. Trying to connect the upper to the lower (in my outdrive stand), I get it to 3 inches apart, twist the yolk and it drops down perfectly .... with a 1mm gap. Everything is greased. I get the 'silver studs' lined up in the front and back as best I can and she just won't go that last mm. Bump it with the hand, wiggle things, hammer and 2x4.

If I lift the upper up and out to try again, I can get the front tight on that silver stud -- and the back gap goes to 2mm-3mm. Lift it up and out, and I can get the back stud tight but the front goes to 2mm-3mm.

I don't want to think the bolts will suck this gap up. Shouldn't the gap close completely?

HELP!!!

 

[Bt Doctur]

Not knowing what drive it is makes it difficult to answer but once you drop the upper on the lower and tighten the side nuts first (Alpha1) there should not be a large gap If an Alpha1 did you grease the water pumps rubber bushing where the tube goes into
1mm is .0394 and that should pull in with the allen bolt under the trim tab

 

[zul]

Alpha 1 Gen 2 (1.81/1.84 SEI 116). There is a suspect block of rubber in the mid-section of the lower. It definately belongs there but It is sticking up and out of the lower drive by 3mm. Seems like it will 'press' into place?

Yes, we greased the o rings in the water connecting unit.

This 1mm gap is solid, it just won't sit proper. Hmm.

 

[zul]

SO , I decided to place the bolts and crank it down. It seems to have worked. Now I've got it on the air pressure test. Fingers crossed .....