Reply To: OMC Shift Rod O-Ring Removal

[aquasonic]

frankr wrote:

I used to make the bushing removal tool but discontinued it because of the wide variations in the size of the hole through the case.  Easiest way to get it out in my opinion is run a 5/16 NC tap into the bushing just a few turns (the end of the bushing that you can see).  Then screw a junk bolt into the threads you just cut.  Flip the gearcase over and use a long punch or rod to knock the bushing/bolt out.  You can reuse the bushing if you didn’t tap it too deep.  Hint: If you can’t reach the tap, use a 1/4″ drive socket extension upside down to extend the tap length.

Frank, I do recall that you had  good reason to stop making the bushing removal tool. The motor I’m working on may be one of the ones where the tool doesn’t work. The hole through the case is barely over 1/4″ in diameter the best that I can tell.

I realized that my attempt at making a tool was not going to work because there would be nothing left of the hex nuts that I was milling down. I may try again with a piece of 5/16″ steel rod, that could be turned down to 1/4″, to fit into the bushing, then stepped up to 5/16″ or so to catch the bushing. At least it will be made from one piece of steel.

The next attempt will involve using the 5/16″ tap, and a 5/16″ bolt. Much appreciated.

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