I removed the lower unit with the engine in neutral

[IZAACTHERETARD]

As the title says, I removed the lower unit in my 1978 mercury 500 while it was in neutral. Now it will not go back together. I've been informed that you're supposed to do it while it's in gear. Anyways, does anyone have any ideas and what I'll need to do to get it back together? Thanks in advance

 

[Mercurylips]

At the top of the page is a sticky on the lower unit gear set up. If you have a factory manual you should be good to give it a try. Using my crystal ball, I think you need to turn your flywheel a little to get the gears to mesh up. I just loosen the top three spark plugs to get mine to turn easy. A little help from a friend may also be in order. Make sure the water tube is positioned in the top of the pump housing and try not to turn your prop and or prop shaft while reinstalling. That will cause you to have no reverse when you do get it to go together. Been through all of this song and dance and the first few times are not easy. I have a 1977 Merc 500.

 

[GA_Boater]

Welcome aboard.

I do mine in neutral cuz it's easier than in forward. Just make sure the remote is still in neutral and the lower is still in neutral. The flywheel turning works for me too.

This the link Lips mentioned, written by merc850 - https://forums.iboats.com/forum/eng...od-of-shift-shaft-setup-for-mercury-outboards

 

[IZAACTHERETARD]

Well I turned the prop shaft a long time ago... :facepalm:

 

[racerone]

It does not matter whether you do it in neutral / forward / reverse.-----You need to make sure that lower unit and control are the same when re-assembling.-----The clutch dog is spring loaded and goes into forward from neutral very easily.----Usually when you are not looking or when lower unit is bumped.----Done this job many times with no issues myself.