Re: 1959 Evinrude 5.5 no neutral?

[Don]

Well, you may have distorted the ID on the bushing causing the shift rod to bind. I’m not sure I understand just how you removed the bushing, there is a special tool made for removal/installation of that bushing, Frank Robb may still have some to sell. Where do you live? Perhaps there is a member in your area who can lend you the tool. It will be tough to judge if the bushing is binding while the gearcase is assembled because it requires considerable effort to overcome the internal detent. Does it seem hard to rock the shift handle back/forth slightly? Go ahead and retighten those shift rod locknuts properly and try rocking the shift handle/lever. Driving the shift rod bushing in too far may have caused the oring to swell which may cause binding as well.
The other issue which may be hard to judge is whether or not the clutch dog fork linkage is correctly positioned into the cradle/collar that rides on the clutch dog. If you decide to disassemble the gearcase again, I would flip it over before removing the shift rod pivot screw and skeg. With the gearcase inverted, remove the pivot screw and the skeg screws. Now, gently tap the skeg off with a soft mallet so the positioning of the fork/cradle won’t be disturbed, it should be fairly clear if the metal fork prongs are properly positioned into the ears of the aluminum clutch dog collar. Another problem may be that the metal fork linkage got distorted from improperly assembly, or perhaps trying to force shift when the clutch dog/gear lugs weren’t lined up properly.