Driven gear shimming tool won't fit.

[jakestevens]

Has anyone had any issues with the driven gear shimming tool fitting into the bore of the upper drive?
I'm using this tool: 91-60526T. The outdrive serial number: OB890738.
The diameter of the tool is too big. I was able to get the tool just past the threads and had trouble working it back out of the opening. The inside of the bore is smooth with no burrs.

 

[Fun Times]

It's a tight fit. Try lubing up the housing and tool a little bit to help get it in and out easier.

Here's the middle of a long "how to" covering an upper alpha rebuild if interested. About halfway down post #16 is some tips that may help.
http://forums.iboats.com/forum/engi...ke-for-6-hours-pic-included/page2#post5875180

Good luck.

 

[alldodge]

Has anyone had any issues with the driven gear shimming tool fitting into the bore of the upper drive?
I'm using this tool: 91-60526T. The outdrive serial number: OB890738.
The diameter of the tool is too big. I was able to get the tool just past the threads and had trouble working it back out of the opening. The inside of the bore is smooth with no burrs.

Haven't used it on an alpha but have same type tool and have used it on my bravo. It is a very tight fit and the slightest tilt causes it to bind. So long as its smooth and lubed and not warped it will go in

 

[jakestevens]

Thanks for the replies folks. I've used lube, I've even freezed the tool, but no dice. I'm sure I could use a hammer an get it in, but I'm concerned that I'll damage the housing when removing it. Since no one has had issues with this, I definitely have something wrong. So, I'll have to investigate further.

 

[alldodge]

Thanks for the replies folks. I've used lube, I've even freezed the tool, but no dice. I'm sure I could use a hammer an get it in, but I'm concerned that I'll damage the housing when removing it. Since no one has had issues with this, I definitely have something wrong. So, I'll have to investigate further.

Is your tool a made by Mercruiser or aftermarket?

 

[jakestevens]

I used an excessive amount of 2-4-C on the inside of the housing and on the tool. The initial fitting wasn't comfortable, but I kept strong pressure on the tool until the back section of the tool entered the housing. Once the back section entered past the threads, the tool insertion was a lot easier and seated against the back of the housing.
So, my problem was that I wasn't using enough lubrication for the job.