forced l/u, stripped coupler, now what?

[lincoln31]

1976 1150 Thunderbolt. After changing impeller, I forced l/u on by tightening the nuts... not realizing that I needed to align the shifter shaft. After install,the throttle/shifter was binding and I couldn't get it into reverse. When I tried to remove the lower end, the shifter shaft was stuck in the coupler. The shifter shaft pulled up partially out of the lower end, but did not come all the way out. I ultimately got it unstuck from the coupler. I pushed the shifter shafter back down into place in the lower unit.
The coupler appears to be a brass fitting. I looked inside and the tines are now stripped because I forced the shifter shaft in. I have ordered a new coupler.
Questions-
1. Is there any trick to installing the new coupler? I haven't seen how it connects to the internal upper shifter shaft.
2. Is my shifter shaft re-engaged w/in the lower unit? How can I check? I started the whole process with the throttle shifter in forward.
3. Should I set everything to neutral for re-install, or forward?

Thanks. I've read many of the threads re. lower units, determining the gear selection, etc. Any info on the the coupler and on whether my shift shaft is still operational w/in the lower unit is appreciated.

 

[Wingedwheel]

Re: forced l/u, stripped coupler, now what?

The coupler should be aluminum. you might have to heat it, 'hook' something over it and tap it dowward and off. They just slip on and become stuck after awhile. You can use some vice-grips or pliers on your lower shift-shaft to turn it, just make sure you pad it so you don't score it. if you didn't pull the shaft completley out of the shift cam it should be fine if its not bent. Turn the shaft CCW for reverse and check to see if your prop locks in both directions. CW for forward and the prop will lock in one direction and ratchet in the other. Re-install with the shifter and LU in neutral with a little grease on the splines of the driveshaft and shift-shaft. Whatever you do, don't force anything. if it seems like its not going on, turn the flywheel by hand slightly and the LU should just pop into place. After you do it a few times you'll be a pro. Hope that helps.

 

[Faztbullet]

Re: forced l/u, stripped coupler, now what?

Usually the coupler is welded to shift shaft and you have to remove powerhead to change it out. Also check the bottom of the block as there is a tab that sticks out to hold shifter in place and if it was forced up it can snap it off damaging crankcase front half and #6 cylinder will suck air....

 

[Wingedwheel]

Re: forced l/u, stripped coupler, now what?

Faztbullet is a welded coupler something that is common in the 1150? I've not dealt with that particular engine, but I've never had a problem popping that coupler off in the several other Mercs of those years I've done. Once heated they came off with a hook and hammer. are we talking about the same one? The one on the bottom of the upper shift-shaft?

 

[lincoln31]

Re: forced l/u, stripped coupler, now what?

Wingedwheel,
Thanks for the reply. Hopefully I can get it off. I hope it is not welded on as Faztbullet suggests!

One more silly question- should I install the water tube in the lower unit first and then guide it in, or should I put the water tube into the motor first and then put the other end into the white tube above the water pump as I'm trying to put on the lower unit?

On a different note, you must be a motor guy? I'm "on the job" myself, though not in motors.

Thanks again for the response!

 

[Wingedwheel]

Re: forced l/u, stripped coupler, now what?

The tube should be in the block first then install the LU. The plastic tube is just a guide to help stab the tube. We've all been "on the job" guys at one time. Alot of things I learned from trial and error, although I've gotten tons of good information from this site therefore I give back when I can. Good luck, after you've put that LU on a couple of times you should be able to do it in your sleep.

 

[lincoln31]

Re: forced l/u, stripped coupler, now what?

Thanks again.

By "motor guy", I meant police motorcycle officer. Your winged wheel emblem is a common traffic officer emblem.

 

[Wingedwheel]

Re: forced l/u, stripped coupler, now what?

Naw, I'm a Redwings hockey fan. You couldn't pay me enough to be an officer in Detroit. I have a real admiration for those guys, or for any Field officers. I took my turn with risks in the military. Now all my excitement come from my teenagers...