Re: lower unit reinstall
put the water tube in the waterpocket cover. the water tube guide in the water pump... that may help... other than that. it's just a plain pain to line them up. i've done several R&R's of the lower to upper while on the boat. the more i've done. the better i get. but rest assured. it's a pain. personally, for me, i feel it's the watertube that hoses me. it flops around and gets hung up prior to going in... food for thought. last time i seperated the upper and lower. i did so on the bench. puttin it back together again i was able to do by myself. second try i think..... much easier on the bench.....
don't forget the quad ring inbetween the halfs or the flat washer on the shift shaft......
so after dons' comment. makes me wonder. are ya mating the upper to the lower? or reinstalling the drive (upper and lower) back on the boat? guess i thought ya were mating the upper and lower, with the upper still on the boat....