Can't get lower unit back on Tohatsu 6 - Help?!

[tessellate]

I took off the lower unit on a Tohatsu MFS6 to inspect the impeller, and now I can't get the drive shaft spline to go back in. I read many other threads where people had this problem, and I have the service manual including diagrams and instructions, but nothing has helped.

I can get the lower unit to within about 1 1/2 inches and then the drive shaft hits something with a clunk. It's not the shift linkage hitting, and it's not the water uptake tube (that's about 1/2" away from the water pump housing gasket). I've tried wiggling the lower unit every which way, turning the flywheel, turning the prop with gear in reverse, and in fwd, and have tried the engine shift linkage in reverse, neutral and fwd.

Very frustrating and now my engine is out of commission while cruising! Checking the impeller should be a simple thing. Anything else I can try to get the drive shaft in? If it matters, I have the engine in the inclined position so that I can work on it. I don't really have enough room to have the shaft vertical while inserting the lower unit.

 

[pvanv]

It's a feel thing. Get the motor as vertical as you can. If you still fail, get a cuppa and relax and try again. Works for me. The driveshaft is hitting the head.

 

[km1125]

Agree with Paul. Just take some time. Much easier if it's vertical. I had to do a 76 Johnson a few weeks ago while it was lying on the ground and I think it took me a half hour to get that thing to line up!!

 

[Sea Rider]

If the drive shaft is already touching the lower crank side while pushing lower leg upwards, it's just a matter to rotate flywheel CW with hand slowly, will see how inmmediately the drive shaft goes fully in. Can drink afterwords all the cold ones that were ready to go for that high tech tedious task. LOL!!

Doesn't matter much if lower leg is fully vertical or not, this process never misses if done as suggested..

Happy Boating