gettting lower unit back together

[trprpat]

I have a 2004 mercury outboard 150. I removed the lower unit to do some repairs. I put the unit back together, but now it won't go into gear. I dropped the lower unit again to see if I missed something. Now, I can't get the gears to line back up. Also, am I missing something else to make it go into gear when together?

 

[m_bickle]

Re: gettting lower unit back together

What repairs did you do? And how far did you disassmble it? If you do not correctly reassemble it with the proper tolerances, shims, backlash settings, when you do get it into gear its gonna break.

 

[1986mariner150]

Re: gettting lower unit back together

I don't know if they are still simular but on mine (1986) the upper shift shaft just slips over the lower shift shaft. To line it up I usually shift it in foward and reverse to get the feel of it then put it in neutral which is in the center. then make sure the shifter/throttle is in neutral before I go back up with it. Has worked every time so far.

 

[mcginleyc]

Re: gettting lower unit back together

Trprpat don't let WOT scare you. You don't need to check backlash unless you have changed lower unit shims or bearings. I am guessing you replaced to waterpump? Did you have the outboard shifted into forward when you initially removed the lower unit? This aids in putting it back in. I believe your motor has a "horizontal" shifting mechanism. I am guessing that the remote contols and the l/u are mis aligned. I can check on the proper procedure if you would like. Just tell me if the motor is carb, efi, 4stroke, or optimax. I have access to lots of manuals in school. Good luck