seized prop, stuck on prop shaft

[Lonestar66]

over the winter i bought a 1967 Mercury 500 outboard to put on my 1966 Lonestar. i need to put new seals and gaskets into the lower unit but the prop is not coming off the shaft. I've let it soak for a few weeks in various fluids (PB blaster, Diesel, & acetone/ATF mix) and it still wont budge. I also heated the prop shaft up lightly with a propane torch.
Any suggestions on removing it without completely destroying the prop since its an 11 spline hub?

 

[Chris1956]

So you tilted the motor up and let the penetrating oil work on the splines?

Next step is to put a 2X4 between the gearcase casing and the prop and give it some firm prying pressure, at against each prop blade. So turn and pry, turn and pry, turn and pry.

If that doesn't get it, use a puller on the prop blades.Maybe a harmonic pulley puller (3 or 4 holes ), and 3 hook bolts over the prop blades, or something like that.

After that, it is cut off the prop and rubber hub and split the brass hub with a cold chisel.

 

[Texasmark]

I made a puller out of a piece of all thread, a chain, 3 S hooks, a dozen or so flat washers to get some space to get at a nut mounted on the all thread. Been awhile but it went something like this.

The chain was cut in 3 pieces, looped around each blade and an S hook attached to each loop for attachment to the all thread. The end of the all thread was ground to a point to fit the detent in the tip of the prop shaft.

From the tip of the prop shaft: Pointed end of all thread, nut, washers, 3 S hooks and lots of grease. Use ⅝ to ¾" all thread. A piece of pipe or lots of washers are to give you some room to get an open end wrench on the nut since the chains are in the way.

Just install all that, put some pressure on it and pull. What may happen is that you pull the shell off the rubber slip clutch and leave it and the brass spline on the shaft. Since you already heated the prop you probably damaged the rubber anyway, including possibly your prop shaft output seals so once you get the shell off, cut the rubber off, and get at your brass.

On the 11 splined hub, I recall seeing props with ll splined hubs. Might check out availability before you destroy your prop....but destruction may be your only answer.....a long time in business prop shop may have a rubber hub with ll splines and can rebuild your prop with a recore. Good luck.