What is the trick to line up a shift shaft during lower end replacement?

[Skidooosl]

84 35hp Merc - I have worked on this for several hours over two nights... I can get the crank and everything to line up but cant get the shift shaft splines to line up allowing the lower unit to go up the rest of the way. Is this a 2 person job? The rod from the motor has a ton of play side to side and its so far up in the housing you cant see when its lined up with the lower end splines! when I push up on the lower end I do see the shift rod move under the cowling so I know that's where I am hanging up at. Looking to hopefully get some tips.

 

[Texasmark]

Re: What is the trick to line up a shift shaft during lower end replacement?

Haven't done a 35. Do you know that the shifter rod and shift shaft in the LU are set to the same gear? If not, N is the best place I've found as the detent is more precise.

If you have them lined up, maybe someone on the top putting pressure on the shift rod would help it to stay in place during the assembly. Otherwise a piece of paper tube slipped over the shift shaft from the top might help. Make one out of a piece of paper and Scotch tape. However, if the shaft is flopping around and you are trying to get it to seat on the splined shaft from below there is nothing to resist the pressure as you come up with the LU. I like the 2 person idea.

Mark

 

[Skidooosl]

Re: What is the trick to line up a shift shaft during lower end replacement?

I like the idea with the paper tube... I may give that a shot tomorrow! I have made sure both are in the same gear and also tried both in Neutral and Forward. I will also try this out with two people tomorrow and hope for better luck.

 

[Chris1956]

Re: What is the trick to line up a shift shaft during lower end replacement?

I never did a 35HP motor either. On the larger motors, you can grab the upper shift shaft with a needlenose plier and pull it into position to mate. On my old 1500, there was a plastic guide that fit the joint between the two levers. If you placed it in the midsection it would center the upper shift shaft. That made it easy to mate as well.