How do you remove the gear from the main drive shaft?

[ranger115blue]

I am having a problem removing the drive gear on the main drive shaft on a lower unit for a 1979 Kiekhaefer Mercury Outboard 115HP. My gear case is cracked so I have to take the insides and put them in my new gear case. I remove the nut but I still cant get the gear off. Can someone tell me the secrets to removing this gear? Any help would GREATLY be appreciated. Thanks Terry

 

[Yepblaze]

Re: How do you remove the gear from the main drive shaft?

If that's like yours.......... <br /><br />

<br /><br />You can bang on the housing (carefully) if it needs some help to come apart<br /><br />

 

[ob]

Re: How do you remove the gear from the main drive shaft?

That looks like the way not to do the job.That pic has got to be from the days when parts were cheap.Hope he's got some soft jaws in that vise. <br /><br />I'd use a gear puller with either soft jaws or a couple of tabs of copper or aluminum on the back side of the gear.

 

[ranger115blue]

Re: How do you remove the gear from the main drive shaft?

Yepblaze, I have taken the prop shaft as in photo 6, but the main drive shaft coming from the powerhead has a pinion gear (I quess you would call it) on the inside of the gearcase. I remove the nut from the driveshaft and but cant get the pinion gear off. I surely dont want to bang on it.

 

[Yepblaze]

Re: How do you remove the gear from the main drive shaft?

You take the bolt off of the pinion gear. Then you still have 22,23,24,25 holding the shaft in the housing.<br /><br />So you get the shaft chucked up in some soft jaws, and drive the housing away from the vice. Two people, one to hold the housing and you using a block of wood held against it and hit that with a BIG hammer.(it's the junk housing anyway right) you can also apply heat to the area around the outside along with penetrating oil. If this is a saltwater unit it could even be tougher. It can look real ugly or mickymouse but they usually will come apart eventually. <br /><br />I know this is probably different than your unit but you get the idea that the stepped shaft is still retained in the housing by the bearing ect. From above.<br /><br />I hope this is helpfull because I don't see your exact model in the manual nor do I have personal exoperience with that particular one. Here was a similar thread where one of the initial images above was used last week at the Old Mercury messageboard. web page Once again it relates to a different but somewhat similar condition. Those guys can be quite helpfull.<br /><br />

 

[ob]

Re: How do you remove the gear from the main drive shaft?

I may be dead wrong ,but from that drawing it looks like the waterpump assy along with # 31 insert needs to be removed to take out the driveshaft with the pinion attached.That insert looks to house the lower driveshaft bearing and the pinion gear won't fit through until it is removed.Unless the pinion just falls off in the propshaft barrel.