Turd Polishing

[MrGiggles]

This is where I left off tonight. Got the motor hung and a couple bolts in it. Need to get a couple washers for the slots in the bottom and it should be done.

Found some magnum fender washers on ebay. Since this motor does not have a clamp, I figured they would help spread out the load on the bolts.

[MrGiggles]

Got the lower unit bolted back on. That Suzuki shift clutch deal is great when everything is in good shape, but if that shift rod gets tweaked a little it's a royal pain.

The outer driveshaft seal was in pretty bad shape, and I suspect water between the two seals froze and pushed it out. I went ahead and replaced all the seals I could without tearing the thing apart. I checked the oil before I bought it and it looked perfect, so there were no leaks.

I hope this is all worth it, been a lot of work. That Merc was pretty much a 50hp with it's tail twisted, and the Suzuki is a detuned 85hp. Should be a big difference.

 

[MrGiggles]

Need some help again Wrench. Got it all put together, oil system bled, and running well, but it just grinds in forward. I tried to adjust it, but even if I unhook the shift cable and push the shift arm all the way forward, it still grinds.

I suspect the corners on that #21 clutch dog are rounded off. 

When you've had these apart, do you just replace the clutch dog, or are the gears usually chewed up too? Looks like those gears come together and they are big bucks.

Guess it's a good thing I bought a whole seal kit for the lower unit instead of just the ones I needed.

[fishinwrench]

Probably need a clutch dog AND a forward gear.   If it was just ratcheting in Reverse then you could get by with a clutch alone.   

The thing that's going to bum you out, is that anytime you replace FWD gear you should replace the pinion gear as well.  You don't HAVE TO...... but you should.   In some cases you can't even buy a forward gear by itself, it comes as a gearset (fwd & pinion).  

The thing to do is disassemble the gearcase, examine the clutch and examine the shift cogs on the inside ring of the fwd gear.

[MrGiggles]

26 minutes ago, fishinwrench said:

Probably need a clutch dog AND a forward gear.   If it was just ratcheting in Reverse then you could get by with a clutch alone.   

The thing that's going to bum you out, is that anytime you replace FWD gear you should replace the pinion gear as well.  You don't HAVE TO...... but you should.   In some cases you can't even buy a forward gear by itself, it comes as a gearset (fwd & pinion).  

The thing to do is disassemble the gearcase, examine the clutch and examine the shift cogs on the inside ring of the fwd gear.

That is the case. There is only one part number for the forward, reverse, and pinion gears, to the tune of $400.

I'll dig into it tomorrow and see what things look like.

[MrGiggles]

This is turning into a debacle.

I got it apart. Had a pretty hard time with the bearing carrier, and ended up breaking it.

I have not gotten the forward gear out yet, but it both the dog and the gear are worn pretty bad.

 

[Deadstream]

Bummer!  That's not going to polish out.

[MrGiggles]

3 minutes ago, Deadstream said:

Bummer!  That's not going to polish out.

There is a slim possibility that it could be welded, but I'm not all that optimistic.

[fishinwrench]

How the hell did you do THAT?!!!! 

We're upside down in this POS NOW!

That's it, you're fired!  😂

[MrGiggles]

13 minutes ago, fishinwrench said:

How the hell did you do THAT?!!!! 

We're upside down in this POS NOW!

That's it, you're fired!  😂

Didn't have long enough bolts to use a puller, had to use a slide hammer and vice grips.

The threads were about half gone from corrosion and pulled on one side. At this point, I had it separated about 1/8", so I tried wedging a screwdriver in there to help it along. Didn't work well.

I got it smoking hot with a heat gun and was able to beat it the rest of the way apart with just the one bolt.

If you're wondering when I'm going to throw in the towel and show up at your place with a box of parts, I ain't there yet.