Can't get lower unit back on, Alpha Gen 2

[Isoprime]

Hi,
I'm trying to replace the lower unit on an Alpha 1 Gen 2.
Seemed to come off OK tho took a bit of shaking. Fresh water and was off last year for water pump.
For the most part a little wiggling for got the lower within an inch of mating with the upper. It seems to be hung up on the splines but no amount of twisting or shaking seems to get it seated.
Tried this maybe a dozen times with no luck.
Odd thing is when I did the water pump it went right back on.
The drive is in fwd and the shaft bottoms out just before the shifter parts meet.

On a side note it would seem a good idea to replace the shaft seals (2 orings?) but how to do this when they are wedged up in the core of the drive?

Also when the boat is in fwd the upper end of the shift is not quite straight front to back. Does this mean I need to adjust the cable (hopefully from upper end) or is it normal to be offset slightly?
Thanks

Nick..

 

[Evinrude Boater]

Re: Can't get lower unit back on, Alpha Gen 2

Take the lower gear case off and look up inside the upper gear case and check the oil seal for the vertical driveshaft. It may have come loose and you've jammed it in the splines. It's the bottom opening in the attached photo.

 

[cr2k]

Re: Can't get lower unit back on, Alpha Gen 2

That and give the prop a little turn ccw (aginst fwd. dogs) to turn shaft to align splines.

Also make sure shift shaft and water tube are lined up.

 

[Evinrude Boater]

Re: Can't get lower unit back on, Alpha Gen 2

Agree with cr2k.

On a side note it would seem a good idea to replace the shaft seals (2 orings?) but how to do this when they are wedged up in the core of the drive?

Two O-rings on the upper horizontal driveshaft or seals on the vertical?
O-rings: Pry old ones off and slide greased new ones on
Seal: To replace the seal, pry the old one out with a seal puller, coat the new one with Perfect Seal and set it with your hand and drive it flush with the bottom end of a socket attached to a 1/2" drive extension.

Should be one O-ring on the vertical driveshaft

 

[J. Mark]

Re: Can't get lower unit back on, Alpha Gen 2

Get a helper to take a 5/8 socket on the crankbolt and turn the engine over by hand to assist in lining the drive splines up

 

[Isoprime]

Re: Can't get lower unit back on, Alpha Gen 2

Agree with cr2k.


Two O-rings on the upper horizontal driveshaft or seals on the vertical?
O-rings: Pry old ones off and slide greased new ones on
Seal: To replace the seal, pry the old one out with a seal puller, coat the new one with Perfect Seal and set it with your hand and drive it flush with the bottom end of a socket attached to a 1/2" drive extension.

Should be one O-ring on the vertical driveshaft

Does anyone know what size these are?
Merc dealer is closed till Mon and my buddy owns a hydraulic repair shop so likey has the size I need.
Its a Gen 2 so no oring on the shaft. Feels like 2 up the shaft hole. Just don't want to pull em out w/o new ones to hand.


Thanks to all who responded on the drive alignment.
Fitting the prop first and turning while lining up did the trick.

Will run a few hrs and swap the oil so will revist the Orings over the weekend.