Can't get lower unit drain plug back in?

[Alaskatrekker]

Hello all,
I have a 1981 40HP Envinrude Commercial unit. I pulled the upper and lower plugs and drained out some old oil mixed with a little water. I had the plugs out for awhile and replaced some fuel lines and spark plugs. Then I went to fill the lower unit and the lower plug will not go back in, there seems to be something blocking the way, any ideas? Did something slip down in the housing? Am I missing something on these units?

Thanks,

Alaskatrekker

 

[F_R]

Re: Can't get lower unit drain plug back in?

Commercial unit, eh? Well I can't say for sure, but it certainly sounds like you are the 127,382nd person to take out the shifter fork pivot screw instead of the drain screw. Now you are gong to have to fiddle around with getting it back in. The fork is what's inside. See if you can get it aligned with an ice pick.. Try putting the motor in various positions to get gravity to help. It usually is possible, but not easy.

Look on the bottom of the "nose" of the gearcase. If you have what I think you have, you will find the drain screw.

 

[AlTn]

Re: Can't get lower unit drain plug back in?

first off..you didn't remove the phillips head screw?....the vent and drain screws are both straight slot. If both were straight slots each has a gasket that resembles a plastic washer and maybe the old gasket is still there and possibly slipped some.

If one screw was the phillips head....you've removed the pivot pin for the shifter assembly. It may be easier to take the engine and lay it on its side. You're going to have to line up the shifter lever hole with the hole that the phillips head pin came out of. An awl, pick, etc. will be necessary as well as possibly wiggling the shift handle. AVOID shifting gears as it is now, before putting the pin back in. Patience is key as you probably don't want to dissassemble the lower unit to get it back in.

 

[F_R]

Re: Can't get lower unit drain plug back in?

BTW, I bought a new pivot pin from an Evinrude dealer the other day. It has a STRAIGHT slot!!! Boy, if we had trouble before, just look out for more to come.

 

[Alaskatrekker]

Re: Can't get lower unit drain plug back in?

First off, thanks for the replies and it looks like I removed the pivot fork pin. I get two holes to line up and the pin goes in all the way but I can't shift the lever into reverse. Any ideas on that? Are there two holes I'm lining up or three?


Thanks in advance


Alaskatrekker

 

[F_R]

Re: Can't get lower unit drain plug back in?

Spin the prop while attempting to shift. Does it go into gear then? Then it is normal. The parts have to be moving to align and go into gear. Not a problem when it is running.