Volvo Penta steering yoke shaft won't fit back into the tiller arm

[simpleur2]

I have a Volvo Penta 290 DP and I needed to change the bushings on the steering yoke shaft. I was able to pry the yoke and shaft down with a couple of large pry bars to remove it from the splined tiller arm. Now when I try to reinstall the steering shaft into the tiller arm it won't fit all the way into the tiller arm. It needs to go in (up) another 3/8" - 1/4" to allow the lower seal to contact the sealing surface on the transom shield. I'm hitting it with a dead blow hammer and it feels like it's seated but it's not. Can't figure out why the same two parts I removed won't go back together.

I got frustrated and took them both to the floor and beat the tiller arm completely down where it needs to go, and I had to literally and mercilessly beat it down to where it's supposed to sit. Then I had to use a puller to get it off. I tried freezing the steering yoke shaft and heating the tiller arm and the arm still didn't seat all the way down on the shaft (and again I had to use a puller to get them apart). Does anyone have some insight on what needs to happen? I mean it's a very simple take it out and put it back in situation. the splines and shaft are very clean and undamaged. I don't get it.

 

[Fun Times]

Have you thoroughly checked for re-alignment to/of the spline notches of trying to get it back together as they were when it came off/apart...Just thinking maybe they are now a bit worn and after much use that they are/were worn in to a set ware pattern making it not want to fit out of sequence...The following steps is out of the 280/290 VP manual...

Step #24. Align the square/the splines on the steering fork with the square in the tiller arm and install into the transom shield.
25. Make sure the square/the splines on the steering fork and the tiller arm are aligned.
26. Using a rubber mallet tap on the steering fork into position.
27. Lock the setscrew with a 5/32 in. allen wrench. The setscrew isn't in the way of installation??
28. Install a new seal (9) and O-ring (7) on the gear wheel.
Install the trim sending unit, gear wheel and gear rack... See chapter Trim System.

If any part of the 2 mating parts just happen to be now a bit compromised from say trying extra hard to get it back together, then the following is also from the manual,:
To ensure the integrity of the steering system the steering helmet is not serviceable as a separate part from the steering fork. If there is a problem with the steering helmet or the steering fork, they must be re-placed as a unit.

Chanching Steering Helmet; Removal - Volvo Penta AQUAMATIC 280 Workshop Manual [Page 150]

Volvo Penta AQUAMATIC 280 Manual Online: chanching steering helmet, Removal. 19. Remove The Sterndrive According To Procedure Elsewhere In This Book. 20. Disconnect The Power Steering (A) If Equipped. Disconnect And Remove The Trim Sending Unit. Transom Shield 21. Loosen The Tiller Arm...

www.manualslib.com

^ If not, maybe lube of greasing them up some will help.

 

[Scott Danforth]

With the pinch bold removed, take a flat blade screwdriver and wedge in the split. It hold it apart to get the splined shaft to effortlessly slip in place.

The issue is now your beating things has galled the shaft.

 

[simpleur2]

Thanks for giving some input. My manual mentions square splines but they are all the same on mine, no odd splines to match up. The tiller arm should be at 90 degrees to the yoke and the grease hole has to align with the zerk fitting (those are the only refferences I have for alignment).

Beating in on is not my normal mode of operation but it didnt result in any galling on the shaft or in the arm. I tried tapping a screwdriver into the slot but didnt get too agressive with it. Today Im going to stare at it some more. So basic and simple, I'm stumped.