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Thanks Bill for your reply. Yes , I will do as you suggested. The more I listen, the more I think the rattle is coming from the power head.
I have had the gear box apart and the gears and bearings are in mint condition, with no signs of water in the oil……….in fact, it was a real surprise as the rest of the motor was as rough as guts.
I don’t have a spare lower unit to swap over, so I think I will drop the lower unit and hook up a hose to the cooling pipe and give her a run and see what the results are.
I may be able to spend time on it later this week and I will certainly report back with the results.
Thanks once again for your suggestions.
Monte NZ