Glenn,<br /><br />You may be correct, but many people think the impeller is too big and it isn't. Stretch out the vanes on your old impeller and see if they look anything like the new one. In order to install the new one you need to lube up the water pump housing well, and then turn the drive shaft -clockwise- as you lower the water pump housing over the impeller. Don't forget the drive key
. The impeller vanes will 'curl-up' inside the water pump housing. Because they are curled up they take a compression set over time, and should be inspected yearly to make sure they are not brittle/broken or excessively worn. I replace mine as part of the winterization process at the end of each season.<br /><br />Best of luck. Happy boating.
<br /><br />Many things have to line up all at once. Don't turn your splined shift shaft on the lower unit. It should still be lined up to go back on. If you turn it now, you'll likely have problems shifting later.<br /><br />If the lower unit won't go easily, try turning the drive shaft a little bit at a time. Likely the splines are not lined up at the powerhead.<br /><br />Watch closely for the water tube alignment. It is -very- important that it gets back into the water pump seal properly. There shoudl be a black rubber guide around the copper tube to make it a bit easier.<br /><br />Normally, you won't be able to turn the drive shaft using the prop. It depends what gear it was in when you removed it.<br /><br />I've invented some new curse words trying to get the lower units back on. Step back, have a beer, and then go at it again. When everything lines up just right it -will- slide in easily.
<br /><br />Can't think of many ways to help.<br /><br />Make sure water & exhaust tube is properly fitted up above, before beginning.<br /><br />With the aid of a flashlight, look up into the midsection at the powerhead driveshaft spline. Make sure there is nothing in the way (could be an old rubber seal from previous installations).<br /><br />When you are installing the lower unit, the first thing to engage is the drive shaft, followed by the shift shaft, followed by the water tube & exhaust tube. Obviously you need to line up the bolting hardware at the same time.<br /><br />Might be helpful to have a friend assist, to save your arms.<br /><br />I've been in your position, and understand your frustration. More beer!
