'64 40 HP BigTwin.<br /><br />I had disassembled the lower unit, in hopes of reinstalling new seals, and eliminate my previous water leak.<br /><br />I replaced the full gamut (plastic fill/drain washers, prop shaft seal and O-ring, drive shaft seal, spaghetti seal).<br /><br />Ran it in a test tank, only to find that water was still intruding (actually more than one problem)...I had assumed it was due to not removing the shift shaft bushing to replace the shift shaft O-ring, though I did manage to fish a new one in place w/ much difficulty. When I went to check, I could see a leak was obvious from the fill hole despite using a fresh washer.<br /><br />A bit dismayed, I was reluctant to tear it apart again, but figured I would for sake of another attempt at removing the shift bushing (which, I surprised myself that I succeeded, since the dealer had failed w/ his tool, and tapping threads didn't do much...but careful wacks at an angle set it free).<br /><br />I attempted to submerge what I thought was a sealed lower unit, and pump in 10 psi...air bubbled up everywhere...it was coming through the water pump housing, which meant it was first coming through the newly replaced drive shaft housing.<br /><br />And I suspect, that the leak around the edges of the drive shaft housing are what led to all the oil being washed out.<br /><br />But here is my problem...removal of the old was easy enough, and it's a press fit.<br /><br />Upon reinstalling the new one, there seems to be too much corrosion (or at least beasically not enough metal left) for it to seat...that's what happened, it dislodged itself from the seat and allowed oil/air around the outside.<br /><br />So what's a reliable fix? Can I epoxy it in place?<br />Not really anticipating digging in there again anytime soon, and even if it were the case, I could always heat and melt the epoxy to pop out the seal.<br /><br />Also...when I sealed it last week...I used the Ultra-Copper RTV silicone (I did this based on my query w/ the dealer about what was recommended. It was strange to me that he said he didn't really have anything available to sell me, and the automotive stuff would work at least as well as whatever was used back in the day to seal it up...BUT, based on what I've stumbled across here, things seem to point away from using RTV...and it seems whatever was the good stuff in the day, is impossible to find...so what can I use?)<br /><br />I was going to try to locate some motoseal grey stuff, I've also seen 3M Marine Adhesive (It's white, and I don't recall the number...but not even sure if it'd handle the task).<br /><br />So, any ideas on how best to secure metal sleeved seals that wont stay pressed in place...and what sort of sealants to use for the rubber to metal bonds. Thanks
