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Can(39)t Get Lower Gear Housing Off - Can it be Saved?-gctid390026

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    Can(39)t Get Lower Gear Housing Off - Can it be Saved?-gctid390026

    I want to replace the impeller on my outdrive, as I think it is causing overheating. When I drained the oil, it was creamy brown (the drain screw had significant particles of metal on it). I ran into a complication as the lower unit will not come off - won't even budge.

    I found 5 nuts - two in the center, two in the front, plus the trim tab bolt is not screwed into an annode and moves up and down, so that shouldn't hold it. I found a sixth nut in the front, and removed it as well, although my manual doesn't say to remove it.

    I don't know how to extract the lower unit. It is almost as if there are more bolts holding it on, but I don't think there are.

    See the picture.

    At this point, I feel out matched. Are there any tricks I should know about? I am debating if I should take it to a mechanic, or would it be wiser to save the money and buy a new outdrive.

    This is a first gen Alpha unit, and by the corrosion I saw, it is original from 1987. I have since painted it. The boat was stored in the water, until I traded my Maxum for it a couple of months ago. The annodes were not replaced often enough. The trim cylinders are badly corroded, and the retaining ring has popped off. The trim fluid was also milky, although now that it is not in the water they may last a while longer.

    Attached files [img]/media/kunena/attachments/vb/693629=28520-outdrive2012 002.jpg[/img]

    #2
    Dave, you are not outmatched. While I'm not familiar with Merc units per se, heat is going to be your best friend when trying to remove something as stubborn as you describe. Assuming you removed all of the fasteners according to the manual, I'd apply heat using a propane torch, making sure the tip of the flame doesn't stay in one spot too long. Just note you will damage paint, but that's easily repairable. I'm sure others will chime in. Best of luck.

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      #3
      Gearshift is in forward, right?

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        #4
        akwalker wrote:
        Gearshift is in forward, right?
        My Clymer manual doesn't say to do that for the lower unit of an Alpha One Gen I. I'll try though.

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          #5
          Astral Blue wrote:
          Dave, you are not outmatched. ... Best of luck.
          Why thank you, Ed! After a nights sleep and a little research, it seems I was not outmatched. The secret is the 6th bolt! It is in the annode recess. With all the paint and corrosion, I did not recognize it. Summary: Alpha One Gen 1 - 6 bolts hold on the lower unit (gear housing), plus there is 7th bolt that holds the Annode on.

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            #6
            Back to the can it be saved question. I found where the gear shaft housing has holes where is eaten away in three places. The three attached pictures show a zoom in. This means that the inside of the lower drive is always exposed to sea water. I imagine that is normal since the exhaust with its cooling water pass through this cavity anyway. Am I missing anything here?

            Attached files [img]/media/kunena/attachments/vb/693758=28549-outdriveB-2012 holes1.jpg[/img] [img]/media/kunena/attachments/vb/693758=28550-outdriveB-2012 holes2.jpg[/img] [img]/media/kunena/attachments/vb/693758=28551-outdriveB-2012 holes3ed.jpg[/img]

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