merc 100 prop shaft removal

[cutter]

This is a red band Mercury 1000 serial # 2413451<br /><br />I'm running into problems removing the prop shaft/carrier assy. I have removed the prop, thrust washer, retaining ring, and thin shim. It is in forward gear, but I can't pull the assy loose. I've sprayed wd40 and let it sit, then tried a slide hammer. It is still in place. I'm thinking the assy must slide out as there is a small square keyway at the bottom. This keyway is rather deep in the groove and I see no way to retrieve it. Is it right to think that the shift shaft does not need to be removed for this? The purpose for removing is to change the seals in the carrier (water in the gear oil). The lower unit has been removed from the outboard and is currently held in a bench vise<br />Thank you

 

[cutter]

Re: merc 100 prop shaft removal

???

 

[hondon]

Re: merc 100 prop shaft removal

This is no spring chicken and as such the simple measures you have taken to remove the bearing carrier may not be enough.You will likely need heat and certainly a puller that hooks around the webs of the carrier.

 

[AtDRiverVA]

Re: merc 100 prop shaft removal

I removed that key by taking the smallest drill bit i could find and drilling in the side between the carrier housing and this key. Just to make a rough spot so i could pull it out enough to grab with needle nose pliers. The bit got wedged between the two and that was great i just pulled the key out! Once that key is out you might be able to rock back and forth the carrier in the housing to loosen. Tilt motor up and spray some break free of your choice and then if that doesn't work take heat gun on a cool morning and heat up your gear case (lower unit) just a bit. The carrier is still cool so that might give you the tolerance you need to just gently grab that carrier without putting much pressure on the seal area, you don't want to miss figure that area much right. Get all that corrosion out of the housing so the O-ring will seat and no compromise due to trash. good luck.