Install lower unit Alpha 1 Gen 1 140 Mercuiser

[4327]

Hi Gang...
I am trying to re-Install my lower unit Alpha 1 Gen 1 140 Mercuiser.
I have watched many you tube videos and also checked for answers here in the old forums.
Looking for advice.
I have my shifter in forward and have also turned the shift shaft on the lower unit clockwise to forward.
Water tube lined up.
Everything else seems to mesh.
Problem is when I tighten it all up I cant move the shifter from forward to nuetral (or reverse of course).
I think the issue is the sliding brass or copper sleeve that joins the upper and lower shifting mechanisms.
Almost seems to be binding at that point.
I also think that I have this brass piece lined up correctly.
It has a cotter pin in it (is that what is supposed to be there?) and I line that up so the head of the cotter pin is facing out from the boat. In this position it seems to slice up and mesh with the shaft in the upper unit.
So I think I have it right.
This brass piece is slightly bent. Is it supposed to be?
Am I doing something wrong?
Any help would be appreciated.
Thanks in advance

Dave

 

[Rick Stephens]

Personally, I recommend you never lift a lower onto a still installed upper. Put the lower in a slotted piece of wood to hold it and lower the upper down onto it. Lifting a lower is a great way to damage the output shaft seal of the upper.

That said, it is super easy to get everything properly into forward gear and then mate the halves when done in a bench fixture. It is literally a few minute job to pull an entire outdrive. And having it all the way off gives you opportunity to inspect and grease u-joints, inspect gimbal bearing and bellows condition.

 

[Bt Doctur]

If you havent damaged the shifting in the lower unit , drop the lower unit and make sure the splined shaft still moves freely.
Reinsert the the lower just enough to catch the forward stud by 2 or 3 turns
Now align the brass shoe onto the splined shaft making sure it is in a straight line
Raise unit up to capture the 2 side nuts and tighten them while at the same time making sure the brass shoe has slight movement up and down and is in the slotted upper half correctly
Tighten side nuts, bottom nuts, front nut, allen under trim tab

 

[4327]

The shaft still moves freely.
I will try it exactly how you said.
2 Questions...
-Is everything else I said on point?
-IIs the brass shoe supposed to be slightly bent or dead straight?

Thanks in advance.

 

[4327]

Oh...and do you have a part number for the "Brass Shoe"?

 

[nola mike]

-IIs the brass shoe supposed to be slightly bent or dead straight?

Thanks in advance.

It should be straight. Got a pic?

 

[4327]

I will try to take a pic and post it

 

[Bt Doctur]

If its bent forward, somebody pried the drive off.
If its bent rearward, somebody tried to force the drive on