Stuck pinion

[Parrothead71]

So I'm finally taking the lower apart on my 76 Evinrude 115hp.
I got down to actually removing the drive shaft, I removed the pinion nut but I can't get the pinion off of the shaft and of course then the shaft won't come out either.
Any ideas?

 

[racerone]

Put your big screwdiver between the end of the driveshaft and clutch dog.--------Now use a rubber mallet on the propshaft and give it a bump to drive the shaft up..----------Driveshaft should now come out.

 

[Parrothead71]

Put your big screwdiver between the end of the driveshaft and clutch dog.--------Now use a rubber mallet on the propshaft and give it a bump to drive the shaft up..----------Driveshaft should now come out.

Worked perfectly! Thank you

 

[boobie]

I used the same procedure years ago but always left the pinion nut on so the screw driver would hit that and not the threads on the drive shaft.

 

[Parrothead71]

So now that it's apart and I can inspect everything I've noticed that I have a chipped pinion.
While pricing a new one I find that there are 2 part numbers listed. How do I know which one I need?
There is no part number stamped on the old one.

 

[racerone]

Any damage to forward gear ?-----I would go with the cheaper " get them off the shelf " part.-------You will need to check shimming to get pinion in the right place.-----Also use " mechanics blue " to check tooth contact with forward gear.

 

[Parrothead71]

Ok I sorted out the pinion part numbers, looks like it is just a chain of partbnumber changes.
So now moving to the shims on the drive shaft. They look worn but how do I determine if I should replace them and what thickness of shims I should get?

 

[racerone]

Installing " dynamic " parts is not the same as installing " static " parts such as sparkplugs.----A shop would have the correct shimming tools to determine what shims are to be used with the replacement pinion. Or you could do the trial and error way using " mechanics blue " to see how tooth contact is.----Your choice on which way to go.

 

[Parrothead71]

Installing " dynamic " parts is not the same as installing " static " parts such as sparkplugs.----A shop would have the correct shimming tools to determine what shims are to be used with the replacement pinion. Or you could do the trial and error way using " mechanics blue " to see how tooth contact is.----Your choice on which way to go.

I thought that might be the case, I've done a couple cars so I'll probably go with the gear marking paint.

 

[Parrothead71]

Found a used driveshaft, getting skeg welded soon.
While cleaning I noticed a small hole just forward of the water pump and what looks like should be a second hole. Should both be open? To be honest I never tried poking at it as I was at work and wanted to get home.

Got my three broken bolts out too but I think I'm going to drill the holes out and put heli-coils in......never rust or corrode on me again.