Ok I think its time to almost wrap it up!
I received the pinion from Nordin and put the LU back together again. Problems I encountered were that the old bearing did not fit former reverse gear as the outer diameter was a few hundreds bigger than the inside of the bearing. Got it machined off and worked like a charme. It now shifts smooth and does not pop out of gear. I also machined the former forward gear which was easier than expected.
Motor runs great, it just needs another tuneup as the lync and sync got messed up again. Anyways, not a biggy.
There is just one more concern:
At the beginning I had no water stream at the tell tale at all. Pulled the LU, inspected impeller key and water tube alignement, nothing seemed wrong. Put it back on and had a water stream. At idle it changes between a really weak and a strong stream about every 3-5 seconds. Took out the thermostat as the water was quite warm but nothing changed. At WOT the stream is strong and well visible. After idling for a bit I cant hold my hand on the block for longer than 2-5 seconds.
Am I having an overheating issue? (Temp alarm never went on)
So far I really want to thank everyone that helped me. You guys have been truely amazing and it is greatly appreciated!
