Shift Shaft Bushing issue

[whatasteal]

'88 Alpha One Gen 1. Found my shifting issue. The top of the bushing disintegrated. Looking for suggestions on how to remove the rest of the shift shaft bushing. The top half was broken up into pieces. The threaded half still in there. See photo. Any thoughts?

 

[alldodge]

Pull the drive apart so the linkage can be removed, I guess

Normally a tool is used

 

[kenny nunez]

Have you tried using a sharp punch with a hammer to rotate the remainder of the bushing?

 

[achris]

Yeah, very common for that bushing to corrode. I've never had one corrode that badly that the Merc special tool would get it out. It's been close a few times though. You may have one that is beyond the normal scope of the tool. You will have to pick away until you get some uncorroded material for the tool to bite onto. Good luck.

 

[whatasteal]

Pull the drive apart so the linkage can be removed, I guess

Normally a tool is used
View attachment 342706

Thanks. I'm afraid I may have to do just that.

 

[whatasteal]

Have you tried using a sharp punch with a hammer to rotate the remainder of the bushing?

I might try this.

 

[whatasteal]

Yeah, very common for that bushing to corrode. I've never had one corrode that badly that the Merc special tool would get it out. It's been close a few times though. You may have one that is beyond the normal scope of the tool. You will have to pick away until you get some uncorroded material for the tool to bite onto. Good luck.

I have the tool but zero left to bite. Thanks

 

[whatasteal]

Appreciate the replies. I'll keep everyone posted.

 

[achris]

Pull the drive apart so the linkage can be removed, I guess

Thanks. I'm afraid I may have to do just that.

Yeah that sounds nice, BUT....

The shaft is splined into the shift cam, and will lift straight out. What stops it coming up is an E-clip on the shaft, just below the bushing. In order to remove the shaft, you must remove the bushing first...

Chris....

 

[Bt Doctur]

you could pull the shaft out and try an easy out and hi heat

 

[Bt Doctur]

see page 3B -8 #44

 

[kenny nunez]

Drill 2 holes 180* apart with a 3/16” bit between the shaft and outer diameter being careful not to damage the threads in the gear housing.
Insert a #1 Phillips screwdriver in each hole then with a large screwdriver between the inserted ones you should be able to unscrew the bushing.
This worked for me.

 

[whatasteal]

Drill 2 holes 180* apart with a 3/16” bit between the shaft and outer diameter being careful not to damage the threads in the gear housing.
Insert a #1 Phillips screwdriver in each hole then with a large screwdriver between the inserted ones you should be able to unscrew the bushing.
This worked for me.

This might be the way to go. I was thinking something similar using a couple of roll pins. Hoping to have some quality time with it on Sunday.

 

[whatasteal]

Used the Kenny Nunez method. Started with 180 degree holes. Would not budge. Heated it up a little, no luck. Ended up drilling holes all the way around. Didn't mess up the threads. Then slowly broke out the pieces. New bushing installed. Good pressure test. I'll slap it on the upper this weekend and hopefully hit the water. Thanks for all the suggestions. Happy boating!