1983 Evinrude 9.9-Cant get lower end back on.

[catalyst-519]

Just rebuilt the water pump on a buddies '83 9.9hp Rude. Now that we're trying to get the lower end back on we're havin a hell of a time getting the shift rod to attach and keep the gears in the position where they're supposed to be. As soon as we get the lower unit bolted back on it only moves half way into forward, neutral gear is forward and reverse seems to be neutral.

As per the Seloc manual when we're joining the coupling with the rod the shift lever is in forward and the gear rod is in the reverse postion to allow for maximum room to get a screw driver in there.

What are we doing wrong here?

Any tips would be helpful. We've tried for hours and still no luck. Seems a bit embarrassing to bring it to the mechanic just to put the lower end back on for us. Any help would be greatly appreciated.

cat

 

[Bob_VT]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

Once you connect the shift rod......... that should be it.

Pull the shift rod up and make sure the gearshift is also in reverse

 

[Cofe]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

Look at this pic.
Did you happen to remove #14 screw by chance?
This is the pivot pin for the shift lever.

 

[Rick.]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

both rods have a bit of an offset so make sure the offset is lined up. I always spread the brass connector a little with a screw driver so the rod slides in easier. Make sure the notch in the rod goes all the way into the brass so the bolt slides through the hole and inline with the notch. The grommet on the water pump also has to line up so the water tube slips in the hole and doesn't pinch the grommet. I sometimes have no problems and sometimes fight it every step of the way. I have found tilting the engine up helps me get it done as well. Keep trying and you will get it. Best of luck. Rick.

 

[catalyst-519]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

Thanks Cofe and Rick.

Cofe: Didn't remove the pin but the rod does seem to pivot and turn in place. Depending on the angle it's turned at, it can stop the rod from moving into gear. You think this may be an issue. Can you shear or damage this pin somehow?

Rick: Maybe that's it, not lining up the offset on the rods. Gonna t.
ry again tonight and re-post if I solve it, or it's back to the drawing board. Hopefully not much more of a fight. Funny you mention that because I just did my own 9.9 and it was as easy as anything. Now that we're trying to do his motor, and it's the same motor, we're struggling. Doesn't seem to make sense.

Thanks for all you input.

Cheers--Cat

 

[AlTn]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

shift handle in reverse...lower shift rod pulled up so that the lower unit is in forward...connect the two with the brass coupling...THEN...reach up and shift the handle into forward and this will bring the the lower unit up and you can put the remaining 6 screws in...that's what I've done...also had the engine tilted as well

 

[bktheking]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

Did one last night, here's the trick. You need to expand the coupler ever so slightly so it doesn't drag on the shift rod. The coupler should be on the lower unit and shifted so the coupler is at it's highest point. Once it is close, move the shift handle on the motor so is lines the groove up for the slotted screw to reattach the coupler.

 

[Rick.]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

And, I repeat, make certain the water tube grommet is lined up or you will be doing it over again. Rick.

 

[bktheking]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

I put the new style replacement grommet on the pump last night, it sits just less than half an inch higher than the original and makes alignment much easier, I will put the gommet on every motor I service.

 

[catalyst-519]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

Do you have the part number for that new style larger gromet?

 

[bktheking]

Re: 1983 Evinrude 9.9-Cant get lower end back on.

Just called the marina 0327035 at a cost of $3.95

Iboats sells it

http://www.iboats.com/Grommet-for-Johnson-Evinrude-327035-GLM-86496-Sierra/dm/view_id.173943