Re: 3.0 merc alignment issue
Alignment tools can be a funny creature sometimes. I've had one with an attitude for years where it slides right in on one transom assembly, then a couple weeks later it doesn't seem to want to play the same when I pull the drive off the same boat. Make sure you check your tool for rust or out of roundness. The 3.0 alignment is also another sneaky engine where sometimes it appears to need to go port to starboard or vise versa but when you go up or down it lines that puppy up just right. I would keep track of how many turns you go up and check alignment every second turn along the way. If it seems to be getting worse, bring it back to where you began then start counting on the way down. If this doesn't work out for you I'd simply try to install the drive again to see how you fare. I am assuming you have an Alpha 1 so remember to have your control box in the full forward WOT position and have the gear case shifted into forward as well. The shift lever on the gear case will be facing straight forward and you will need to gently spin the prop counter clockwise to lock it in forward gear manually. Seat the gear case as far into the transom as you can, while making sure not to bump the prop in the clockwise position or it will kick out of gear, then force your prop counter clockwise to rotate the gears to help align the splines with the coupler if they haven't done so already all while putting pressure on the gear case to set it back into place. I'm sure you probably already know the install procedure, but figured I would post it for you in case this is your first attempt. Good luck and let us know how it worked out for you.
