problem solved – Gear Case too tight

[John]

Thanks one and all for the precautions and great information.
I am pretty embarrassed to say, but, a few posts back (don’t remember what thread)
I talked about pounded out the brass bushing from the forward gear,
#1 issue: I was using the Prop Shaft and hammer to get it out……..
It seems I deformed the butt end just enough to make it bind in the carrier.
#2 issue: I did use some gear oil so not to install anything dry.
But, this my first actual total overhaul of any gear case, and I have assembled
and disassembled the arrangement a dozen times to make sure I have everything
in its correct place…… Also, I have the gear case from a ’60 40hp on the table also.
Sort of cleaning and such together……. In my golf ball sized brain, On one assembly,
I could not find a missing Thrust Washer so I reached over and got one out of the 40hp
tray of parts, knowing the missing washer will turn up after I clean off the work table.
Not knowing that the original Thrust Washer was "stuck" in place from the oil in the gear and I did not see it.

SOOOOOOOOOOOO – – – With a deformed shaft and a double washer, it is a wonder anything fit at all.
filed down the shaft butt as true as I cold get it, polished with Wet-n-Dry paper, assembled everything
with a brush of oil, tightened all bolts, the shaft turns normal and true. Torqued the bolts down to 13 foot pounds,
everything still turns free as it should, with some resistance from the new oil retainer seal.

So, after I calm down from being so aggravated at my OWN stupid mistakes, I will CLEAN OFF THE WORK TABLE,
double check everything again, part by part, reassemble with 847 Sealant and new spaghetti seal and be done with it.
Then, do the same with the 40hp . . . . GGGRRRRRrrrrrrr I could spit grapes !!!

Hope everyone has a Happy, Prosperous and Safe 2016 !!

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