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#253103
Don
Participant

    US Member

    Did you try assembling without the pinion in place?  If the prop shaft/driveshaft rotates freely then it is safe to assume that there is some sort of fit/backlash issue with the pinion and or gears.  Did I hear you say you replaced the forward and reverse gears as well?  Perhaps there is an issue with the fit of the gears to the pinion.  Are you sure you got the correct gears?  Again, these gearcases all seem pretty similar, but there were a few changes.  I guess at this point, if the old pinion/gears aren’t destroyed to the point of never fitting/turning, I would be inclined to assemble with the old gears and pinion…  I would compare the new and old parts very carefully.  perhaps there is an issue/defect.

    Sorry, you can not add any shims/gasket between the skeg and upper gearcase housing, that won’t work.