Evinrude 115hp 1996 Impeller key is getting damaged

[DWilks]

The drive shaft space for the impeller key seems to be too low. The key ends up between the o-ring and the impeller causing the key to get damaged by the metal plate that surrounds the shaft. Seems to me that the key should be above the o-ring. See pic to explain. Also, I may have damaged the part that the drive shaft slips into on the top side of the shaft but can't find any mention of what it is or exactly where it is located or how to get to it to check for damage to possibly replace it. I've looked at the drawings on this site and I also have the Manual by SELOC of the J/Evinrude Outboards 1992-01 Repair Manual. Any help on both problems would be appreciated.

 

[racerone]

The driveshaft is too far down into the lower driveshaft.-----Need to check and see what is wrong first.------Wrong driveshaft / wrong lower unit casing etc, etc.

 

[flyingscott]

You have something put together wrong. That o ring does not go there, that is usually at the top of the driveshaft if needed. The plate should be lower than the key slot. Need to look at diirections.

 

[racerone]

That o-ring goes there on some models.

 

[DWilks]

Thanks for the replies. The impeller kit comes with that o-ring and states that it does go where I have it. Pic shows that. So, guess I need to take the gear case apart to see why the drive shaft is not up where it should be. There never was an o-ring at the top of the shaft and no groove there for it. Any help on the question of what the drive shaft top fits into on the crank case and how to get to that to inspect? The prop does turn rev and fwd when the drive shaft is turned by hand. Thanks for helping.

 

[DWilks]

I will take the crank case apart tonight or tomorrow and report back on what I find. And probably have more questions. Thanks

 

[flyingscott]

The pic shows how it should be. I hope you mean the gearcase.

 

[Faztbullet]

That should be a 2 piece shaft, look like its been push past snap retainer or its missing

 

[DWilks]

Yes, I meant Gear case. I tried taking the prop shaft out to get to the nut that holds the drive shaft in but can't figure a way to get the clutch dog out to get to the nut. Also, what releases the prop shaft so that I can take it all the way out?
Also, the drive shaft is the original shaft that's been in it since I bought the boat 5 years ago. I had one side of the trailer jacked up taking a wheel off and the boat flipped up and the motor hit the concrete and broke 3 inches off the bottom of the keg.

 

[racerone]

You have to take the nut off with a 7/8" combination wrench !!!---Then remove the driveshaft.-------The propshaft and forward gear comes out as an assembly..----There is no other way.-----Shift rod must be pushed all the way down and then screwed out of the lower unit too.

 

[DWilks]

Thanks for responding racerone. Are you saying that the shift rod must come out before I can take the propshaft out? That would make it a lot easier to get to the nut holding the driveshaft because as you can see from the picture, there's not much nut to grab!

 

[jakedaawg]

If you dont have the pinion nut tool a 7/8" tappet wrench will do. The pinion gear has to come off before the prop shaft can be removed. A tappet wrench is a long thin open end combination wrench. You can also grind one down. I am not positive on the 7/8" size. Racer probably correct though. Hes super good.

 

[racerone]

You have to pull up on the driveshaft to fit the wrench in there !!----I use a standard 7/8" open end wrench.----Will take that nut off all day long.----And no the shift rod has nothing to do with taking the nut off the bottom of the driveshaft.----I have done this more than once !