Prop Shaft Problems 84 Merc 200HP

wcsd106

Petty Officer 2nd Class
Joined
Mar 27, 2010
Messages
182
I posted in the prop section, but I have determined that this is not a prop related issue so I'm posting in the Merc section.

I have a 1984 Mercury Black Max 200HP Outboard on a Champion Bass Boat. I was finally able to give it an on the water test run last weekend and was met with disappointment. The boat would not get onto plane and was feeling like it was slipping but RPMs would climb. The two individuals with me and I all came to the conclusion that the hub was spun.

After getting the boat home, I removed the prop nut and washer and removed the prop. The prop came off of the prop shaft without any difficulty.

After dropping off the prop to be re-hubbed on Monday, I purchased a spare prop (Hopefully to be used as a primary) that was a pull from a similar year model mercury outboard.

After getting the new prop home, I noticed that the prop would only go onto the prop shaft about 3/4 of the way before it stopped and bound up.

Today I received a call that my old prop was repaired. I brought the new prop to the prop shop to have it checked out as well. Both the new prop and the newly re-hubbed prop slid without effort onto a prop shaft that the repairman had in his shop.

After getting home I tried to install the newly re-hubbed prop to my mercury outboard. It now has the same problem as before; gets to within about 1 inch of the end of the splines and then binds up and will not move any further onto the shaft.

I have cleaned off the prop shaft and checked it for burrs. It looks fine but obviously there is some sort of problem with it.

This morning, before I picked up the re-hubbed prop, I took the boat and new prop to the local dealer to have one of their service techs look at the prop. Two of their mechanics checked out the prop and I was advised to take a file and try to clean up the spline edges on the prop shaft. I did as advised but was worried about taking too much off of the edges so I have barely run a file across it.

I will be calling my prop mechanic tomorrow to see what he thinks. I'm hoping that I will not have to replace the prop shaft, but at this point I can't think of anything else that would really fix this.

I am still confused as to how the old prop was able to slide on and off of the shaft without problems, but after the new hub was installed it doesn't slide on anymore.
 

Faztbullet

Supreme Mariner
Joined
Mar 2, 2008
Messages
15,937
Re: Prop Shaft Problems 84 Merc 200HP

am still confused as to how the old prop was able to slide on and off of the shaft without problems, but after the new hub was installed it doesn't slide on anymore.

The splines where worn in old prop...
 

wcsd106

Petty Officer 2nd Class
Joined
Mar 27, 2010
Messages
182
Re: Prop Shaft Problems 84 Merc 200HP

Since it looks as though I may end up having to have the prop shaft replaced, would it be wise to go ahead and attempt to file the existing shaft splines a little more aggressively and see if I can get the props to fit onto the shaft?
 

Hackamore

Cadet
Joined
May 14, 2010
Messages
23
Re: Prop Shaft Problems 84 Merc 200HP

Get a small three cornered file and keep it laying fat on the surface of the spline. You can see where it is cutting and where it is not cuting. Make sure it is laying flat to the same angle as th splines. Out on the very end you can even champher the very ends back a little to make it easier to align the prop splines.
Good luck.
 
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