How do I remove the shift shaft?

[couturierjm]

This boat...new to me but old. This problem is with an Alpha one Gen 1. I have replaced the water pump etc and noticed when took the lower off it took a little umph to get it to come the last inch or so and it pulled the shift shaft down with it. I am familiar with mercruiser lowers and re-installing. Everything is in forward, the shoe in the bell housing is oriented correctly. When everything is together, it refuses to shift. The shifter works smoothly with no lower on it, I watch the upper shift shaft turn with ease. . I can shift the lower from forward, to neutral, to reverse when it is off the boat. When assembled? Nada. I think the shift shaft (bronze one with the shoe) is bent. I cannot for the life of me figure out how to get it off. Any ideas? I have included a pic of the part.

 

[Bt Doctur]

Did you remember to turn the spllned lower shaft fully clockwise while turning the prop CCW for Forward?

 

[Rick Stephens]

The intermediate shift shaft, your picture, is held in just by a circlip underneath. You have to split the cases to get to it.

I always recommend that you pull the entire sterndrive and split the cases with them held in a slot on a workbench.Just a couple 2x6s 3 inches apart will do it. It is so much easier than lifting the lower up to the upper while on the bopat. And simpler to jkeep everything aligned in forward gear. Besides which, it is a 10 minute job to remove a sterndrive and the same to reinstall. Too easy and keeps from wrecking oil seals as you try to cram a lower up into place.