Re: Lower Unit wont go back on
FUn aren't they? Exact same thing happend to me with the 2 brass cam pieces. They only go one way, and I found it easier to put one piece in the leg (held with grease), and the other on the lower leg.
Now I haven't actually fixed my motor yet, since the only way I could get the lower leg to go the extra inch to fit tight, was to turn the shaft out of neutral. I now know that it was just a matter of 'jiggling' the shafts so they would inter-lock.
The lower legs shift shaft fits into the motor side. Now the problem is that the lower shaft wasnt fitting into the upper shaft, since they were likely just a bit off. I'll paste the advice I found that I'm going to use soon. Note that he says its sometimes easier to disconnect the shift cable from the control box, to take the load off the linkage. I think I'll try that right away.
Heres the advice ( by emckelvy -http://forums.iboats.com/showthread.php?t=127624);
Sometimes the upper shift rod gets pushed up; make sure it's pushed all the way down and seated fully in the bushing and the adapter plate. It'll be obvious when you look at the shift arm, underneath the bottom carb.Don't pound on anything or you'll ruin the internal splines in the shift rod and never get it together.
Best way for the novice to align the parts is to shift the lower unit to neutral. Move the shift shaft CCW until it clicks into neutral. Move the control box lever to neutral.You will of course have to turn the flywheel clockwise to engage the driveshaft into the crankshaft splines when inserting the lower unit.
If you still have trouble aligning the shift shaft, sometimes it helps to
disconnect the shift cable and 'jiggle' the shift arm back and forth a bit.
Sometimes there's a bit of 'preload' on the shifter with the shift cable
connected, and this can interfere with the perfect alignment of the upper and lower shift rods.
Hope it helps, and I'll follow up once I try mine, maybe tomorrow.
