Shift shaft orientation

[petvetdoc]

Trying to reinstall lower unit I removed 3 months ago to replace water pump.
1986 Johnson 140 HP.
The dogleg in the shift shaft is supposed to point forward, away from the drive shaft, correct?
When I slide the lower unit on, the shift shaft won't go forward enough(toward the front of the engine) to go through the hole in the plate under the crankcase. Is there a rubber grommet there that could be twisted or out of position? If so, how do you remove, reinstall or reposition?
It seems to me that the dogleg in the shift shaft is hitting the front of the tube through the midsection, keeping me from starting the top of the shiftshaft up into the hole in the plate under the crankcase.
My best guess is either crud in the tube is keeping shift rod from moving all the way forward or top of shift rod needs to be bent slightly forward. I can't believe that rod could be bent though.
I have never had trouble getting one back in before other than aligning the shift rod bolt.
I guess removing the lower pans would make it easier to pry on it but I sure hate to start using force!

 

[boobie]

Re: Shift shaft orientation

I've seen this happen when the lower motor mounts get corrosion behind them, swell up and push the exhaust housing out of line.

 

[Bosunsmate]

Re: Shift shaft orientation

Have a look up the hole from the bottom poke a thin bit of fencing wire up.
Drop the carbs out and have a poke around form the top, maybe something dropped in there, with the top clear you should be able to get a drill into it

 

[petvetdoc]

Re: Shift shaft orientation

There appears to be a rubber piece in the hole below the carbs. Is this essential? Can you remove it?

 

[boobie]

Re: Shift shaft orientation

The rubber piece is there to keep water out and it is split. Take a long needle nose and just pull it out. After you're done with the job just pop it back in.

 

[petvetdoc]

Re: Shift shaft orientation

Pull the rubber seal out from the top after removing carburetors? Then try to grind the hole out some at the back to clear the shift shaft? Is that the approach to take?

 

[Bosunsmate]

Re: Shift shaft orientation

Try pulling it out and putting in a replacement before grinding

 

[boobie]

Re: Shift shaft orientation

The approach to take is to check those lower motor mounts.

 

[petvetdoc]

Re: Shift shaft orientation

OK, I'll get the carbs off and report back.

 

[boobie]

Re: Shift shaft orientation

Curious. Can you post a pic from the side of the lower motor mounts ??

 

[petvetdoc]

Re: Shift shaft orientation

Having trouble posting picture, however, I tilted the motor back down which seemed to put things more in line and I was able to line everything up. There appears to be some play in the steering arm(?). I was able to pry that a little and get the shift shaft passed it up into shift connector.
Was a pretty light fit till the dogleg got clear past the steering arm, then everything fit nicely! Thanks for all the help!