Pinion gear is off but wont come out of bullet

[Brown99666]

First post. I usually search and find answers to questions without having to ask but . I am replacing the pinion and forward gears on my E90DPGLAF. 2020 EVINRUDE E TEC 90, with the S2 type gearcase. All service manuals and youtube videos show the pinion gear basically falling out of the gearcase once the driveshaft is removed. But mine is just bumping into the dog clutch. And it is impossible to remove. Tried switching forward , reverse , neutral, shaking, wiggling, tapping, twisting. Theres got to be something I'm missing, and I'm sure it's something simple but I'm overlooking it.. any suggestions would really help.

 

[racerone]

With clutch dog fully in FORWARD it should come out.

 

[Brown99666]

My cousin called his dealer shop and found out they use a board to pry the prop shaft downward with the dog clutch in the reverse position. I used a 2x6 ripped in half and a bottle jack to apply the force needed to clear the pinion gear.

 

[Faztbullet]

Never had to use a board or jack to disassemble these..rubber mallet yes. Why are you replacing gears anyway?

 

[racerone]

+++ on the above.----What happened to the gears ?

 

[Brown99666]

Some under water obstruction took a chunk of my prop blade, twisted the prop shaft splines, and knocked out a couple teeth on the gears. The pinion on this gearcase is different than anyone here had ever seen. They were used to seeing smaller gear with a nut fastening it from underneath. But this one is a larger gear with threads tapped into it and a bolt fastening it from the center of the lower half of the 2 piece drive shaft.

Got to admit it was a pretty sketchy idea to use a jack, but There wasn't much resistance on the jack. after it worked though, i realized i could have got the same effect with a bar clamp. I just needed a constant force holding the prop shaft out of the way while I fumbled with the gear.

 

[racerone]

Took one of those apart a while ago.---Had to figure out the way it bolted on there..-----No brute force required to remove pinion here.----The new pinion will need to be shimmed correctly.