Crank protector, Flywheel Puller, and lifting eye. 85hp merc

MercMark

Petty Officer 2nd Class
Joined
May 20, 2003
Messages
149
I'm about to tear into my powerhead. The manual calls for a crankshaft protector, flywheel puller and lifting eye. It lists mercury part numbers. Are there real world alternatives to these parts/tools.<br /><br />I'm about to try and separate the powerhead/lower unit in my garage. I don't have a cherry picker or overhead hoist. I could use some tips on doing this. How many guys will it take to lift the powerhead. or will I be able to separate them without having a some sort of hoist pulling up on the powerhead while I loosen the bolts.
 

Hooty

Rear Admiral
Joined
Oct 2, 2001
Messages
4,496
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

I use a harmonic balance puller and 1/2" drive air impact wrench to pull the flywheel.I made a lifting eye out of a bolt the same size and threads as the puller bolt in the center of the harmonic balance puller and welded a couple of flat washers to it. If ya need, I can post a foto of it. I use to rent an engine hoist (at $25/day) but then I found a brand new one at Northern Tool for less then $200 so I bought it. A couple of guys could probably life the p/h off if it wasn't stuck but if it hasn't been off in several years, it's gonna be stuck.<br />Hope this helps.<br /><br />g'luck & c/6<br /><br />Hooty
 

MercMark

Petty Officer 2nd Class
Joined
May 20, 2003
Messages
149
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

Ok, so I talked to the local marinas and mercury no longer has record of the part numbers for the flywheel puller and crankshaft protector cap. So two questions.<br /><br />Does anyone know how to find out the thread and size of the hole in the flywheel so that I can make a lifting eye and get the right puller.<br /><br />And<br /><br />What does a crankshaft protector cap look like? I need to know so I can fabricate something to do the job.<br /><br />My engine serial number is 7033755<br />Flywheel puller part No c-91-48501a1<br />Crank protector cap part no. c-91-24161
 

Hooty

Rear Admiral
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Oct 2, 2001
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4,496
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

The flywheel should have three equally spaced drilled and tapped holes around the center of the f/w. Those holes are probably 1/4"-20 or 1/4"-28. Loosen the f/w nut 7-8 turns but don't remove it. This will protect the threads. Bolt the three fingers on the puller to the three 1/4" holes in the f/w. Snug the bolts down good but don't bottom 'um out. Screw the pulling bolt down until it's tight against the center of the crankshaft. Put the 1/2" drive air impact wrench on ther puller bolt and hammer away. When ya get the f/w loose, replace the puller bolt with the lifting bolt and remove the powerhead.<br /><br />g'luck & c/6<br /><br />Hooty
 

MercMark

Petty Officer 2nd Class
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May 20, 2003
Messages
149
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

air impact tools huh?....<br /><br />me cave man. no impact tools.<br /><br />Uhh.. serioulsy though. Impact tools are just not in my budget. I don't do enough automotive work to justify it. If it's absolutely required I'll borrow my dad's.<br /><br />Are they requried? I think I could throw myself against a big ugly johnson bar pretty hard.
 

jim dozier

Lieutenant Commander
Joined
Jan 8, 2003
Messages
1,970
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

If you don't have an impact wrench you can use a breaker bar to remove the flywheel nut, and tighten the center bolt on the flywheel puller. When the puller bolt is good and tight whack the bolt with a hammer.<br /><br />I pulled the powerhead on a DT85 Suzuki with a small comealong. After I got it off, I was able to pick it up by myself and lay it on the bench. I'm 50 and no football player, so 2 guys can do it piece o' cake. You can also try chaining the powerhead to a rafter, and then cranking up the jack on the front of the boat (which will lower the rear) to separate the powerhead from the middle unit.
 

farginicehole

Chief Petty Officer
Joined
Apr 15, 2003
Messages
482
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

I bought a cheap harmonic balancer puller and actually twisted/bent the puller bolt by torquing it with a big ratchet. Flywheel was really stuck on there. Ended up having to pay a marine mechanic $50 to remove the flywheel for me! That sucks. What a waste of beer money.
 

Hooty

Rear Admiral
Joined
Oct 2, 2001
Messages
4,496
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

Yep, that sucks, especially when you can buy a 1/2" drive air impact wrench for $24.95.<br /><br />c/6<br /><br />Hooty
 

MercMark

Petty Officer 2nd Class
Joined
May 20, 2003
Messages
149
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

Ok point taken.<br /><br />But when I add up the cost of tools and parts that I absolutely need to do this job (which I don't have because I used to use my dads when I was in school) It all adds up. Not to mention that an impact wench requires more that the impact wrench itself to use it. Now I start looking at a tank for my compressor, quality regulator, lines, quick change fittings.....<br /><br />it adds up. If I can minimzie the capital here it will help.<br /><br />Thanks for your helpful posts hooty. Sorry if my inexperience is trying your patience.
 

jim dozier

Lieutenant Commander
Joined
Jan 8, 2003
Messages
1,970
Re: Crank protector, Flywheel Puller, and lifting eye. 85hp merc

You can get an electric impact wrench.
 
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