1996 mariner 125hp

[sandcrab277]

we've followed the repair manual to remove the lower unit and determine why the unit is making noise when shifting from neutral to reverse...total of 5 nuts removed...according to the book, it should come right off....it appears to be frozen and gentle tapping with a block and hammer on the inner part of the fins near the studs doesn't help to loosen it...the port side seems to open a small gap but no success on the starboard except forward of the front stud...any suggestions would be appreciated...this unit has never been apart before so there may well be corrosion internally...we've sprayed with pr buster...

 

[quantumleap]

Re: 1996 mariner 125hp

Try to use wood shims where it is separated and don't be shy with the hammer! If you have too, wrap the biggest rubber mallet you can find with a rag and strike the back-top of the lower unit to get the other side to loosen. Tighten and loosen the port side to help wiggle the other side loose. It is the driveshaft splines that get seized, and you have to be aggressive to free it up. Good luck. BTW a clunk or slight noise from N to R is not that unusual.

 

[sandcrab277]

Re: 1996 mariner 125hp

quantumleap...thanks for the input...i doubt any rubber mallet would work better than a 5 lb sledge and a 2x6 chamfered to get as close to the inside edge of the fins...its really on there solid... we've even had a thin steel wedge in the port side to no avail...wood shims are useless...i guess the next step is taking off the midsection to get the drive shaft splines to loosen...

 

[JB]

Re: 1996 mariner 125hp

Moving to Merc/Mariner Troubles.