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#62062
hotrod
Participant

    There are a few different styles of lower unit.
    On the most common one: the lower unit aluminum casting is removed by first removing the prop nut and lock washer. Then remove the prop and its key by sliding it straight off the shaft (it is keyed). Then loosen the bolt and nut which squeezes the casting onto the main tube. The casting can then slide or twist off the driveshaft tube theoretically. It might help to unscrew the brass water pump in the casting. This will allow the pump spring to come out and the heavy brass piston, and more lube can then be inserted there. (The pump piston rides on a cam on the hollow driveshaft.) Use some penetrating lube on everything. You could apply heat on the aluminum casting with a propane torch until the lube starts smoking. This will loosen the lower unit some. Lube some more. Tapping on the casting upper edge will be needed, using a piece of wood and a light hammer. If nothing moves you can try sliding a small screwdriver into the open end of the ‘squeeze’ slot gently, to widen it slightly for lube to penetrate, but don’t spread the slot much or it could crack the casting.
    The driveshaft/prop shaft has a thrust surface and bronze thrust washer on it which is sandwiched between the end of the main tube and the aluminum lower unit casting. This means that the casting must come off the main tube in order to get the driveshaft out of the lower unit casting.
    The main tube is inserted into the casting about 2 inches.
    Best wait until I see pictures.