Can't get the lower unit back on...HELP!

[Luke415]

So water pump was rebuilt, now trying to put the lower unit back on my Merc 150XL OS 2-stroke. CAN'T GET the shift shaft splines to go correctly into the housing. Not talking about the driveshaft FYI. Driveshaft goes in fine (as I turn the prop a bit), but I can not get the shift shaft in. I almost got it in a few times but it was misaligned and ended up going into neutral. Here is what I am doing:

-Shifting throttle into forward
-Turning shift shaft to engage forward gear (45 degrees CLOCKWISE on my counter rotation outboard) At this point the prop is clearly not in neutral, and is spinning in forward motion
-Insert lower unit, inserting drive shaft and lining up water pump pipe...
-At this point, the only way I can get the shift shaft to go into the housing is by having someone back off on the throttle towards neutral (This moves the housing just enough counter clockwise so that the splines can go in. Then when I push the lower unit the rest of the way (takes quite a bit of strength and jiggling), the prop spins freely as it is now in NEUTRAL. Obviously the splines are not fitting in the housing correctly

Is this an issue with the shift linkage perhaps, or something related? From all the research I have done, it should not be this difficult...ee

 

[Dukedog]

put both "shifter" (makin' sure slide is between tha neut. marks on tha anchor bracket) and gear case in neutral... insert gear case enough ta get one or two nuts started... align shaft shaft with with gear case shift rod and slowly push and/or turn nuts ta start up with it.....
some swear tha only way is in gear and some do tha same with it in neut..... i like neut with a remote start button!.. ones that say its a snap have probably done it more than a coupla times!!!

 

[Chris1956]

Sometimes you need to pull the shiftshaft into position using a pair of needlenose pliers. However, as Duke says, I prefer neutral for both the gearcase and the shifter, as it cuts down on the movement of the shiftshaft. You can turn the flywheel to align the driveshaft.

 

[GA_Boater]

Vote #3 for putting the gearcase and remote in neutral.

The method with the needlenose pliers Chris describes works for me every time. Neutral and turning the flywheel is so much easier and goes together the first time. Using forward is a try and try affair, which was always frustrating because the gearcase shaft pops out of forward so easily.

 

[Luke415]

Thanks everybody. I'm gonna try it in neutral and see what happens!

 

[James R]

I really dont know about your motor but in some cases I have had to disconnect the shift cable and manually position the shift slide to get the spline line up.

 

[Dukedog]

I really dont know about your motor but in some cases I have had to disconnect the shift cable and manually position the shift slide to get the spline line up.

on these its best ta leave tha shifter hooked up.... eliminates movement ya don't won't.. with both in neutral or gear (your choice) should be no need ta "turn" anything, thats when ya get in trouble.... jus a slight wiggle maybe (and two more hands for tha first timer).. tha splines, both male and female have a very slight taper on tha ends that takes guess work outta tha question.... tha big problem comes when tha unknowing or first timers get ina strain/panic tryin' ta get tha thing back together... jmo

 

[Luke415]

Got it! Thanks everybody. Now my Port side (Twin engines) neutral throttle button won't work. Quicksilver brand, can't find a model or serial number. F!!