Getting lower gear housing back together.

[dsims]

Just rebuilt the water pump on my 86 alpha one drive and am having difficulty getting it back together now. I left it in forward gear and now cannot get the lower foot to go all the way up, it stops about a half inch short of going all the way up. I dont see anything hanging but think maybe the drive splines or something with the shifter is hanging and not letting it go all the way back up. Any advice or experience with this?

 

[JustMrWill]

Re: Getting lower gear housing back together.

In no way an expert...and know NOTHING about mercs...but it sounds like the splines aren't lined up...try wiggling the prop shaft alittle to try to get it to fall into place.<br /><br />I am sure someone will be by shortly to correct me.<br /><br />-JustMrWill

 

[dsims]

Re: Getting lower gear housing back together.

tried wiggling the prop shaft to no avail.

 

[Bt Doctur]

Re: Getting lower gear housing back together.

whatever you do, DONT force it. <br />make sure the shift is engaged on the splines.(lower unit in fwd gear)did you grease the rubber bushing in the waterpump cover that the copper tube goes in.you will need to turn the prop backwards a bit to line the splines up. (impeller lubricated so the vanes dont reverse themselves.)

 

[jwaymer]

Re: Getting lower gear housing back together.

Sims,<br />I have had my Alpah lower off 3 times in the past two weeks. Putting it back on has been a task. Are you trying this by yourself or with help? I tried once to do it by myself but could not. Bottom line was that I needed someone constantly turning the prop while I pulled up on the lower to get the spline to mesh. Make sure your shifter linkage is also lined up correctly and that the water tube is in the guide correctly. Doing this by yourself only leads to frustration and beer. I'm sure the seasoned experts might disagree...except for the beer part maybe.

 

[Haut Medoc]

Re: Getting lower gear housing back together.

Turn the prop shaft ccw and the shift shaft clock wise before you try to mate them. Make sure the shift shaft stops turning. This is forward. Get them close and make sure the upper shift is facing directly forward. You may[probably] have to turn the prop shaft ccw slightly to get them to mate. DO NOT FORCE THEM! When you have it right they will go right together easily. The tube and washer [ as outlined above] are very important as well. Don't forget the washer that sits on top of the shift shaft..........J

 

[lakelivin]

Re: Getting lower gear housing back together.

Don't know if this will help at all, but thought it worth mentioning.<br /><br />I was having a very difficult time putting the top & bottom half of my Cobra drive back together. Only issue was reisitance from a rubber bushing the water tube went into and two o-rings on the drive shaft. Even with gear oil on them it just didn't want to slide together. Was puttig all my weight on the upper while working it side to side a bit but still had problems with the last 1/2 to 3/4 inch.<br /><br />Pulled it apart & put some AstroGlide (an, ahem, adult lubricant; VERY slippery stuff) on the bushing, o-rings, & relative tubes.<br /><br />The upper slid into the lower like a hot knofe through butter. If you get the shaft aligned & it's a friction problem, might be worth trying.

 

[tommays]

Re: Getting lower gear housing back together.

<br /><br /><br />i find it much easyer to just place the whole thing on the bench so i dont miss the water tube or screw up the quad ring<br /><br />you can also do a better pressure check with the drive off to be sure you did not miss the quad ring that seals the upper and lower or any other small but fatal mistake<br /><br />and it lets you check the rest of the drive for problems while there small<br /><br />tommays

 

[thunderroad]

Re: Getting lower gear housing back together.

I had the same problem with my Mercruiser 160 last week. I found it easier to do with the prop off. It seemed I had to turn the prop shaft quite a bit before the splines lined up. I was just wiggling it slightly at first but then actually started turning it in a CCW direction. After about a 1/2 turn it slipped right in.<br />I did it by myself but would rather not do it that way again.

 

[vicsponjr]

Re: Getting lower gear housing back together.

How much force is forcing it????? I got it up to where I could start the two nuts in the back, turning the prop ccw, turning the nut, till the prop locked. At that point I assumed (hoped) the spleens lined up. Then I, and I don't recommend it, bumped the drive up a bit and slid a jack under it. I jacked it up only enough to apply the same pressure I was using lifting it when I started (94 degrees here)and bounced it around a little until whammy! It slid up. Hopefully everything else will be OK and it will be easier next time.