Bad coupler, warped splines? Alpha one gen 1

[m1dn]

Hello,

Old 1991 Glassport with 1989 2.5 ( 120hp ) Mecruiser.
Boat started making grinding noise.
Took alpha one off, replaced gimbal bearing and ujoints, now can't get it back on.
Alignment tool goes in n out smoothly.

Took gimbal bearing and shaft off the alpha, it barely engages into couple and won't go it.
Tried moving engine up/down, no luck.

Looked with flashlight as much as i could, don't see any warps, scratches nor anything wrong with coupler.

What would be my options?
Kick the shaft in to try and unwarp splines or this is a lost cause?

It's an old cheaper boat i got recently, replacing coupler is not an option, it would probably end up costing more than boat is worth.

 

[Bt Doctur]

usually it still not aligned correctly. Does the tool go in fully and bottom out?

 

[zellerj]

You need to give the prop shaft or prop a little twist to get the splines to align. It helps to have the drive at the same level as the gimble housing - adjust by moving the trailer tongue up and down. Make sure the drive and the control lever are both in Forward.

 

[m1dn]

You need to give the prop shaft or prop a little twist to get the splines to align. It helps to have the drive at the same level as the gimble housing - adjust by moving the trailer tongue up and down. Make sure the drive and the control lever are both in Forward.

Shaft is off drive and gimbal is out, shaft itself won't even go in, don't think alignment would play much role in this case

 

[nola mike]

Shaft is off drive and gimbal is out, shaft itself won't even go in, don't think alignment would play much role in this case

I mean, if it's that hard to get in there, how TF did you get it out? Is there a ton of grease in there? Did you verify nothing else in the coupler cavity? I don't know how the splines would warp--they're aligned with the shaft.