Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

[cprodave]

Recently in order to remove a stuck Impeller from Driveshaft (which I did so with lubricant, heat and tapping with visegrips) I had to pull the Driveshaft out of the Gearcase. Driveshaft will not go back into Gearcase. Normally I would remove #3 Bearing Housing Assembly 391171 from the Gearcase which would allow me to realign all components including Gears and Driveshaft. However The Bearing Housing Assembly is really tight--maybe even due to 30year-old factory paint (Gear Oil is fine, no water leakage, i.e Seals are OK). On another 6hp motor while needing to disassemble within Gearcase I bent the Bearing Housing assembly (while prying ) So I am really hesitant to take this Bearing Housing out of the Gearcase. But I will if I have to.
So 2 Questions: 1) is there a trick/tip to getting the Driveshaft to drop down through/into lower components such as #9 Lower Driveshaft Needle Bearing 32528 and/or #14 Pinion Gear 326211? As an FYI with gentle force I can rotate the Prop Shaft Clockwise, but not CCW--hoping the splines on the Driveshaft will fit into the Pinion Gear or whatever is obstructing. But no go. 2)is there a tip to nondestructively removing the #3 Bearing Housing Assembly from the Gearcase ?

Thanks in advance.

 

[oldboat1]

Just a hunch, but might invert the gearcase to insert shaft.
(hunch, meaning I think I've done it that way, but don't specifically recall....)

 

[racerone]

Agreed ----Turn gearcase upside down.-----Push up on shaft while rotating the shaft.

 

[cprodave]

Thanks Oldboat and Racer. I did as you recommended and it worked-- but only after I placed the Gearcase (minus the Driveshaft, WaterPump etc) into the Midsection and worked the Gearshift Lever back and forth (Neutral/Forward--this has no Reverse) a couple times. Then I was able to fully insert the Driveshaft into the Gearcase and proceed with installing Water Pump.
Question: how crucial is #8 ShiftRod O-Ring 321357 and #10 ShiftRod Bushing 326207? What is so special about the Bushing (around $20) material or dimensions, etc? I bought this motor used (OK--abused) and the O-Ring and Bushing are missing. I don't want to place an order for just these 2 items if reasonable substitutes can be used. If function of these 2 items is to keep water out of the Gear Oil I would think a tight PressFit rubber plumbing washer with a tight-fitting O-Ring (#4 or #5?) below would suffice. Am I wrong?

 

[Crosbyman]

designed with the parts 8-10 to protect the gearcase oil....

better invest a few $$$ and run the motor for more years of enjoyment.

 

[cprodave]

Crosbyman, ok I ordered parts, should arrive by Tuesday 3/23. I found the Bushing for only $10 including shipping--not so bad. Looks like a simple brass bushing with counterbore on one side (I'm assuming this goes underside to capture the O-ring which appears to be size #4). Thanks.

 

[cprodave]

I installed the Brass Bushing with O-ring underneath on the Shift Rod. Even with the Bushing installed as high as possible on the lowest dogleg bend of the Shift Rod there is a "sticky" action when i move the Shift Lever backward to Neutral position (backward pushes the Shift Rod downward). Previously with no Bushing installed there was a " positive feel" shifting into Forward and positive feel shifting int Neutral. Now there is a positive feel only when shifting into Forward (Shift Lever forward = Shift Rod moving upward).
Is this "mushy" feel normal when the Bushing is installed correctly? How far up from the lower end of Shift Rod should the Bushing be installed? BTW i would think installing the Bushing as high as possible (to prevent mushy feeling which may disallow shifting into Neutral) defeats the purpose of keeping water out of Geal Oil...
Thanks in advance...

 

[oldboat1]

Try rotating the prop counter clockwise by hand when dry shifting into gear (motor off).

The bushing should install at the O-ring (O-ring should fit in a groove in the shift rod).

A little marine grease on the shift rod might help -- new O-ring may be what you are feeling. There is a possibility that the clutch spring just ahead of the forward gear may be broken, and need replacement.

 

[racerone]

The shift handle and shaft have a detent.----This would be clearly felt when shifting this motor without lower unit attached.----With lower unit attached it might be a wee different.----Should not change by installing a new CORRECT o-ring.

 

[cprodave]

Racer, yes detent is best way to describe the tactile feedback that is now missing when going into Neutral. Detent worked perfectly for several years when unbeknownst to me the Bushing and O-ring were missing. I confirmed it is a 3/16 ID with 5/16 OD O-ring that I installed. I can feel the detent working when Lower Unit is not installed, or when Lower Unit is installed but with Bushing/O-ring missing. I have not tried with Bushing but no O-ring installed.
Oldboat, I didn't turn the prop CCW but jumped ahead to water tank testing. It's a bit hard to tell due to water flow/disturbance from Blubber Hole (this motor has no Telltale) but it seems I may be finding Neutral OK. I hope to do on-the-water test later this week. There is no groove in this Shift Rod. However I can see discoloration on the Shift Rod where previously some owner had the Bushing/O-ring installed. I did apply grease to the Shift Rod in this area and I installed the Bushing/O-ring at this area. I sure hope the Clutch Spring isn't broken!
I will update again after on-the-water test. Thanks for ongoing help.

 

[cprodave]

Adding photos...

 

[racerone]

I am going to be blunt here.-----You need the bushing and the factory o-ring to keep water out of the gearcase.----There is nothing wrong in the way they built / assembled this motor.---I can't believe that you would think of running it without the bushing or o-ring !---Use the factory o-ring !--Put it back to factory original; and it will work fine for years to come !!

 

[cprodave]

Racer, yes --agreed. I would rather have the engine not going into neutral with fully functional detent vs. getting Gearcase ruined by water intrusion.