Re: shift shaft problems
Following the proper way to reseat the shift shaft you have to remove the bearing carrier to reseat the shift shaft into the shift cam. This requires special tools and is not an easy task. That said, I have heard of a method that allows you to reseat the shaft without tearing out the prop shaft, bearing carrier and all of the parts leading down to the shift cam.
Disclaimer: I have never tried the following. I have HEARD that this is possible. I have no idea if reseating the shift shaft in this manner will work or if it is good/bad for the lower unit. There are other people on this site that are far more versed than me that will probably weigh in on this.
The thing that is stopping it are the parts blocking the cam that are held in place by a spring against the sliding clutch. It is spring loaded. You have to compress the spring to seat the shift shaft down against the shift cam. When you turn the prop shaft and it makes that clicking noise you are moving up the ramp of that sliding clutch and compressing that spring. When it clicks the spring returns to its rest position.
To reseat the shift shaft, you have to turn the prop shaft to the point just before it clicks (where the spring is in its fully compressed position). The shift shaft should slide down the rest of the way on the cam and you should be able to tighten the shift shaft bushing.
