Re: resealing my lower unit
No other way to describe it! That damn thing frequently gets stuck and it can be a bear to get out. See: There are two O rings sealing it to the gearcase and the lubricant gets hard. Then if that isn't bad enough, the aluminum corrodes, jamming it tighter.
Chrysler had a warning to remove the spool yearly (with salt water use) to prevent a corroding spool from splitting the gearcase. That's how tight it can get.
You need to TRY a couple of lengths of 1/4 inch all thread with a tool you will make. Cut a chunk of steel at least 1/2 inch thick and about 2 X 4 inches. Drill a center hole to clear the threads on the prop shaft but ride on the splined land, about 9/16 plus a smidge larger. Drill two more 5/16 holes to match the distance of the anode screw holes. You will find it necessary to drill the holes in the spool through, and tap them all the way otherwise for sure you will strip them. Then put a couple of nuts and washers on the plate and tighten. What? It still didn't come out? No surprise!
Try some heat while tightening the nuts. When you strip the anode holes, re-tap to 5/16 and use that size all thread. Spray the Pee Eye double Ess out of it with penetrant. be sure to speray in the water intake slots to get the inner O ring and spool flange. Alternate heat and penetrant. One took me a couple of days spread out over a couple of weeks. Not a pleasant job, but eventually you will prevail! And no! You can not just slip an O ring over the prop shaft. Shame on you! You KNOW nothing in life is easy and everything fights you.
