Tips for putting lower unit back on?

[jitterbug127]

I’ve been tinkering with outboards the last 6 months or so. I’ve owned 10 or so and have changed out the water pump in nearly all of them. The one job I struggle immensely with is getting is lower units back on. This has been for 4, 6. 9.9, 15, and 25 hp motors. I can’t ever seem to get the shift linkage to rod to match up properly and subsequently I’ve stripped multiple screws trying to get the shift lower unit back together. 99.9% of the time I’m extremely diligent to start threads in reverse and strip anything. Am I the only one that struggles with the this and does anyone have any pointers? I’ve watched plenty of videos in the topic. I did actually struggle to get the lower unit back on the one mercury I worked on as well.

 

[kbait]

I always spread that coupler open a bit with a screwdriver before re-mounting gearcase. Upper shift rod should slide right in (move shifter handle toward forward), use a flashlight to align shift rod detent to coupler bolt hole and insert/tighten coupler bolt.. good luck!

 

[racerone]

I use clutch dog / rotation of propshaft / moving of shift lever to line up the hole and the notch.----That way the bolt will not strip !----Learned that simple method about 50 years ago.