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Re: Can't get lower unit off a 1976 evinrude 135hp
Several things I would look at would be the Sacrificial Anodes may hold the 2 parts together and then look at the water intake ports. There may be extra bolts behind the water inlets.
You may want to remove the engine from the housing to cut the weight when wrestling with this. You may be able to pull the driveshaft with the engine and get the linkage and water tube out of the way. Sometimes there is just a slip together joint on the driveshaft. If you cut the shaft you may have to open the gearbox to replace it. $$$$
There are some Salvagers on the Net. You will need them to replace what you break. You could contact them on the secrets to getting this apart. Hopefully you will find a hidden bolt to solve all of your problems.
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Evinrude used a shift mechanism located in the lower unit that is actuated by a rod up to the linkage in the motor housing. It could be stuck anywhere along the way or the gear that shifts on the shaft could be immobile due to rust and corrosion.
Under Lower Carburetor is a Bolt Going Through The Shift Rod Remove This Bolt--Then Undo All Bolts Holding The Lower Unit--The Lower Unit will Then Come Out Don't Turn The Shift Shaft As It Is Threaded And Will Change The Set Length,If You Do Have To Remove It Then Crew It Fully In Counting The No Of Turns So That You Can Set It Back To The Original Position Good Luck
There is 2 things.The gearbox linkage has a plate on the side of the leg to undo.The other is the splines on the end of the g/box,that goes into the crankshaft,are seized.Your motor being a 76 might have seized splines.Hope it isn't,but hope this helps
Okay this is on total memory. The shift shaft for a lot of those engines goes right up through the pilot shaft and exits just in front of the block under the carburetor(s). You will see the **** linkage arm connected to this shaft sometimes it's double nutted. See if you can slide the lower unit back up to the housing and put a bolt in it to hold then undue the shift shaft linkage, Remove the bolt and drop the lower unit. Be careful of the water tubes and check make sure the rubber grommets are in place in the pump housing not on the tubes. Clean up the pump housing and install the new impeller kit. Put the impeller down the shaft on top of the impeller plate, lightly grease the inside of the housing the impeller plate and impeller. Then lower the pump housing down to the impeller while turning the drive shaft clockwise lightly push down on the impeller housing. This will fold the impeller blades all in the correct position and provide lubrication to the pump until the water gets into the pump. To make life easier re-grease the drive shaft spline and the water tube grommets this will ad ease in reinstalling the lower unit. be careful to make sure you thread the drive shaft, water tubes and shift shaft all in at the same time. After installation you may find you need to adjust the **** linkage.
below the carbs is the shift rod and take the small pin out , then remove all bolts that hold the gear case to the leg then drop the unit and place in a vice to hold by the skeg fin below the prop ! normally its the edges of the gears and the central slide clutch that wear, remove and have re cut at machine shop ! saves buyin new gear set !! check all linkages ok for wear FIRST though !!
You could take off the lower unit and leave the boat home. All they need is the bottom. The propshaft seal can be cut from fishing line. There should be another seal on the shift assembly and a third on the powershaft. Some you could do, but the shop can pressure test before and replace only what you need. Then pressure test after the repair to verify it seals.