Engine-outdrive alignment tool doesn't fit???

[ReefRaider]

My ex-certified mercruiser mechanic friend let me borrow his alignment tool. It doesn't fit! A first for him he says. 1993 350 5.7 Merc / alpha one. I mic'ed the ID of my coupling and got 1.300 inches. Mic'ed the shaft of the tool and got 1.375. Outdrive shaft mic'es out at 1.275. So, what's up? Hoping one you experts has an easy explanation. Leary of ordering a new tool, afraid I'll get what I got. My friend whom lent me the tool, and has never seen it not fit in this appication, suggests having it machined down to the 1.300 and then it's mine (he's retired). Just looking for some insight as to this issue if someone can help. Is my (are) outdrive couplings different, are there many choices in them? I looked the tool up for my engine and only see one, probably the one I have that doesn't fit. Thanks in advance.

 

[bigskiohio]

Re: Engine-outdrive alignment tool doesn't fit???

how did you mic your coupler it has splines? There are specs on this forum search for them or google image and you will find print.

 

[Don S]

Re: Engine-outdrive alignment tool doesn't fit???

I've had several aftermarket couplers that were unusable. 2 were EMP, one was Sierra.
I could use the alignment bar in them, but even a used outdrive shaft wouldn't go into the splines. The sad thing was, it was all on the same boat. Went to OEM and put it together. Was sick of pulling that engine out and changing the coupler.
We now install OEM only, if someone wants to buy an aftermarket for their own use, fine, but we won't install them. Or if they want us to, we charge for 3 engine pulls if it takes it to get one that works.

 

[PitchFork]

Re: Engine-outdrive alignment tool doesn't fit???

From what I have found before I Machined my alignment tool in the manual shows the tool first part that goes into the coupler is 1.010" in diameter for 2.2" long and then 1.150" diameter for 2.750" and then 1.375" diameter for the rest of the bar.

 

[bigskiohio]

Re: Engine-outdrive alignment tool doesn't fit???

can,t you check them before you put them on? I bought a aftermarket and tested it ,I don't like the fit feels a little loose . will run it this year and install oem next year. Going to do repaint so engine will come out anyways.