1992 Force 120 gear case cover removal - advice please

[Mytox]

Hi there. I'd posted this previously, and I'm really looking for advice on how to safely remove the gear case cover on my 1992 120 Force, so that I can access the fitting to reconnect the shift shaft which was unscrewed and removed. I had some instructions from Jerry but I was concerned about wrecking seals and whatever by not really knowing what I was doing. Any advice is truly appreciated.

Dry Docked since last August....Rando

 

[Frank Acampora]

You need to remove the water pump. Then you remove the two bolts from the front of the cover and pry up on the center section where the water pump was. There are no pry points so you must tap in a fine screwdriver and pry against the lower unit casting.

I always get a bit confused as to years so if the housing has two bolts at the rear and one bolt at the front, remove them and again pry..

The center section has an O-ring seal which most likely will remain usable. The front has an O-ring in a groove and again, you should not destroy it. However, be certain it is clean and dry, then coat it with some sealer before assembling the pump base onto the lower unit.

 

[Mytox]

Removed water-pump and cover as per the instructions in the first sentence above. I sharpened a small screwdriver and gently tapped and pried. The gasket tends to keep things stuck together. Once the cover was off, I was able to clearly see to the bottom of the shift shaft chamber and the fitting....a nut welded to a yolk type assembly mounted on a pivot. The nut was no longer oriented 90 degrees to the shift shaft installation position. It had tilted on the pivot and was easily reoriented with the threaded end of the shift shaft which then could be screwed back in, and being careful not to over tighten. O-rings were good etc. Old gasket scraped and cleaned and new gasket made. Everything went back together no issues. Transmission functions ok.

I'd post a picture of the shift shaft yoke fitting at the bottom of the gear-case but this site doesn't seem to accommodate that. It's no wonder I was having problems rethreading the shaft into the nut without being able to see it and and then reposition it.

JerryJerry had mentioned that as a final step I should do a pressure test. Not sure what the best way to that is....