lower unit installation

[andrewterri]

I changed my gimbal bearing and lower shift cable today. Alignment is good and depth of tool matches same depth as old bearing. I checked and the new bearing fits the drive shaft prior to installing, however, now the lower unit will not go on. I have about an inch to two inches before it fits tight to bell housing. I made sure to put oil on the two O-rings on the shaft. What is going on? Do I just use a size 13 mercrusier precision impact tool and just kick the heck out of it? When it is as tight as it will go and I remove the shaft it is lining up on the splines and is about 2 inches in. Thank you guys in advance for all your help. We can't afford to pay a shop 600 dollars to do this. The boat is a 89 sea ray 160 with a 3.0 and alpha one outdrive.

 

[alldodge]

Alignment cannot be correct with the drive being that tight. The alignment tool has a tighter tolerance then the input shaft on the drive. If the alignment bar goes in as it should the drive will slide in easier.

Where di d you get your alignment tool and do you know it is correct?

 

[wrench 3]

I assume that the shift lever is in forward or you wouldn't have got the drive off. But have you checked to see if the tab on the drive is still lined up in forward.
If that's OK, a size 13 may be deeded. Some times the new "O" rings can be a little tight going into the bearing. But nothing bigger than a 13.
I just reread your post and noticed the new shift cable, so make sure that the slipper on the bell housing is lined up fore and aft.

 

[NHGuy]

Did you follow the book on installing the cable?
Did you make sure the drive and the boat are in forward gear? And did you get the shift slide to engage the shift link on the drive as it went together? That's what keeps the shoe and foot at the correct angle for sliding into each other.
If the drive won't stay in forward you can put it in gear and the apply some backward tension on the prop with a bungee. That will keep it from falling out of gear.
Hope you didn't over grease the splines, if they are too heavily covered the splined shaft can't go all the way in to the coupler because the air can't get out. Mercruiser says to just do some grease on the splines but stay away from the tip.
Once you are comfortable that everything is right, put a couple of whacks on the back of the drive. Mine are usually in nice condition, so I use the heel of my hand to smack it home.

 

[andrewterri]

Thank you guys for your quick replay. The o rings are the old ones. The shaft is lining up on the coupler and going part way in up to where the o rings hit the bearing. I have ensured the all linkage is clear and moving loosely. Drive is in forward and I am watching the applicable linkage. I bought the alignment tool online and I do not have micrometer to check the size. Everything is the same as the old bearing expect lower unit won't go one. Could the inside of the bearing be a tighter diameter and since it's new and not worn like the old one and that's why it's tighter?

 

[Bt Doctur]

the gimbal bearing is not lined up to the coupler just yet. the alignment tool should slide in easily all the way..

 

[andrewterri]

The alignment tool slides in and out easily. It goes in until the 2nd ring bottoms out just like it did with the old bearing

 

[andrewterri]

I am going to try and remove some of the grease from the coupler splines and the shaft splines. I have used a lot of grease but none on the tip of the shaft.

 

[NHGuy]

Did the align tool go all the way into the coupler? The gimbal bearing needs to be angled so the tool can be slid right in to the coupler.
If it does not slide right in you could need to align the engine with the adjusters in the mounts. Alignment adjustments are a very typical step.

 

[Rick Stephens]

I have also seen too much grease in and under the o-rings on the shaft prevent the o-rings from going into the gimbal bearing. Not as likely with old o-rings, but they only need a light coat on the outside, not in the groove.

Rick

 

[airshot]

Have had this issue on a number of occasions, sometimes it helps to have another hand to rotate the prop which in turn rotates the shaft to lineup the splines. Everything needs to be perfect....when they are it will just slide right in. Two summers back I spent 3 hrs trying to get mine on only to find a very simple and slight turn of the prop made it fall into place.

 

[alldodge]

You probably don't have tool 91-863372 to check perpendicularity, so install the alignment tool all the way in, then start the motor and see if it wobbles. Don't do it very long and you don't need water for a 10 second run

 

[andrewterri]

I will check everything you guys recommended. The alignment tool goes in until the second lip bottoms out behind the gimbal bearing. It did the same with the old bearing not to say that means it's correct. The shaft goes into the couple about 2 inches before it gets stuck. Almost like the bearing is to tight. When I put it on the shaft before installing it took some pressure to get it over the 2 o rings but it did fit.

 

[Bt Doctur]

if it goes in 2 inches and get tight, the alignment is still off a bit. Can you obtain another inputshaft. If so and you believe everything is correct drive it in fully till it bottoms out. If everything is correct it will remove with finger pressure.
If alignemt is off you will have to pull it out

 

[andrewterri]

But which way do I know to adjust the motor?

 

[Bondo]

But which way do I know to adjust the motor?

Ayuh,.... Ya grease the alignment bar, when ya pull it out, look at the tracks in the grease, 'n adjust the motor to even out the grease tracks,....

 

[andrewterri]

I checked everything you guys suggested and it checked out. I got the drive put on and had to tap it in until the bolts were showing where I could tighten it down. Went to the lake and when I turn the wheel to make a tight turn I here a tick,tick,ticking come from the back of the boat. Any ideas?

 

[Bt Doctur]

you binding the U joints from a mis-alignment. Installing a drive by tightening the nuts to draw it on may lead to coupler failure or U joint failure.
Your best bet is to remove the bolts and hope the drive literally falls right off .DO NOT PRY IT OFF

 

[thumpar]

Make sure you don't have a bunch of old grease in the coupler too.

 

[andrewterri]

Thank you. I will take it off in the morning. As soon as I heard something was wrong I only drove in a stright line to the trailer. The boat never went past idle. If the drive is stuck do I just try to tap if off? Obviously the cheaper alignment tool I bought is worthless.