prop shaft removal

[SEGAangler]

I've got a 1987 Evinrude 140 (E140TXCUA). I had a seal failure on the lower unit which ultimately led to seized bearings and a snapped driveshaft. I've replaced the lower unit and I'm using the damaged unit for my own personal learning experience by disassembling it. I cannot remove the pinion gear; I cannot remove the pinion gear nut because there is no shaft to hold to keep from turning. Is there any way to remove the clutch dog pin or disconnect the shift pin or related parts to remove the prop shaft with the pinion gear still in the housing?

 

[boobie]

Can you still rotate the prop shaft and forward gear ??

 

[SEGAangler]

I can rotate the prop shaft and also push it in and out a bit; the fwd gear doesn't seem to be engaging on the dog though

 

[boobie]

Pull the shift rod up and see if you can get it forward gear.

 

[SEGAangler]

I got fwd gear engaged. Unable to turn prop shaft with it engaged; the fwd gear is jammed/seized

 

[boobie]

Oh Chit. If you could rotate the prop shaft with it in forward gear there is a way to get the pinion nut off. Try it again. Maybe there is a piece of something jammed in it.

 

[SEGAangler]

It does not turn easily but I can get the shaft and fwd gear turning. The pinion (which is basically just dangling on the dog) seems to be adding to the binding. If/when we get to loosening the pinion nut do you know that size off hand? (I may need to go in the morning and get a wrench).

 

[boobie]

13/16" or 7/8" sort of rings a bell for the open end wrench. Also get a pipe wrench (borrow one).

 

[racerone]

7/8 wrench.------Weld a nut on the shaft to turn it !!!

 

[boobie]

Depends on where the shaft broke.

 

[SEGAangler]

The shaft is broke way down in the housing; at or near the taper? I've got a pipe wrench (I used it to get the shaft turning in gear). I'll hafta nab a 7/8" in the morning...all I've got larger and smaller

 

[boobie]

Put the G/C in forward gear. Put the wrench on the pinion nut and rotate the prop shaft counter clockwise with the pipe wrench. This should break the pinion nut loose. If you get it loose, leave the nut on with a few threads. Then shift into neutral and jam a big screw driver between the nut and the clutch dog. At that time give the prop shaft a good rap from the bottom. This should knock the pinion gear off of the drive shaft. Let us know what happens.

 

[SEGAangler]

I got the pinion gear off and also got it loose from (what is left of) the driveshaft. Everything is loose but it seems the pinion doesn't quite have enough clearance to drop out. As it tries to come down the fwd gear pushes it forward and it jams on the gearcase.

 

[boobie]

Have you got it shifted back into forward ??

 

[SEGAangler]

Yes sir; I've even used a large screwdriver and tapped the fwd gear and dog both to ensure they were all the way back in the gc

 

[racerone]

With the clutch in forward and the drive shaft portion out of the gearcase the pinion basically fall out on the floor.

 

[boobie]

Have you tried pulling down on the prop shaft and wiggling it ??

 

[SEGAangler]

It finally JUST came out. It was just wedged in (this LU has sat a bit since failure). Does everything else just slide out the front....any special steps to take? If it simply slides out this one will require a little "coaxing!"

 

[boobie]

Push the shift rod down (rev) . After you put it in reverse, remove the shift rod and then pull like hell

 

[SEGAangler]

It's being a real bear, which I expected. I have PB blaster sitting in it for now. Thank you for your help and info guys it was extremely helpful. There really won't be much to update on from here as this disassembly was merely for personal growth and learning.