evinrude 140 hp v4 lower unit removal problem

[edred]

I have an 81 evinrude 140hp v4 2 stroke and am trying to remove the lower unit to replace my water pump and cannot seem to separate the case..I have the factory repair manual and removed all necessary bolts including the shift linkage bolt underneath the carbs and the hidden bolt under the trim tab...I am able to separate the case about 1/4 inch but thats it...I have tryed rotating the driveshaft by grabbing the flywheel and moving it back and forth while a friend is pulling on the lower unit with no luck...I tryed in vain for a few hours at times being quite forceful and it really seems like something is binding and holding it back ..if anyone has had this experience I would appreciate any advise ...thanks

 

[Haffiman]

Re: evinrude 140 hp v4 lower unit removal problem

Sure you removed the correct shift linkage bolt?
Can you see if the shift rod has moved down from the linkage?
It might be hanging in the splines, try to knock in some wedges between the leg and housing.

 

[cdn-pk]

Re: evinrude 140 hp v4 lower unit removal problem

the connector on top of the shift rod (part that you disconnected) might have got caught under the cowl, i'd say in the tube in the midsection but it sounds like you haven't lowered the gear case low enough yet. can you see the shift rod lowered in between the lower cowling and the upper mid section?

 

[Joe Reeves]

Re: evinrude 140 hp v4 lower unit removal problem

The shift release bolt on that model would be a long shoulder type bolt with a 3/8" hex head that has a screwdriver slot in it. If this is the bolt that you removed, then you removed the proper bolt and the shift rod is free.

If the above holds true, then your problem is that the driveshaft splines are rusted tight in the crankshaft splines. If this is the case, sometimes the shaft can be freed by working it back and forth (up/down) but that can be exhausting. Many boaters have went as far as to remove the engine from the boat, turn it upside down, then run some kind of peretrating oil to the driveshaft so that it runs down into the spline area.

This problem is usually caused by someone not installing the O Ring on the top area of the driveshaft or not greasing those splines thoroughly or both. At any rate, that's a hellava problem and I wish you luck.

 

[edred]

Re: evinrude 140 hp v4 lower unit removal problem

Thanks for your advice...I was successful in removing the gearcase today with myself pulling as hard as I could while my helper shook and rattled the lower unit back and forth for about 20 minutes...at first the progress was slow and barely noticeable but with perseverance it finally let go...you were correct in predicting the driveshaft splines were rusted to the crankshaft splines as the splines were all dry and red when I saw them..your advice put my mind at ease as I couldnt erase the nagging thought I was missing something...THANKS

 

[Joe Reeves]

Re: evinrude 140 hp v4 lower unit removal problem

Glad to her that you managed to drop the lower unit without cutting the driveshaft, dismantling the lower unit to install another shaft, remove the powerhead to get the remainder of the shaft out, etc.

You were really lucky. Now, be sure, after cleaning the splines, to grease them thoroughly and install that O Ring.