exploded view of gear case

Roller Bearing housing

Roller Bearing

Forward coil

inserting forward gear

forward gear

Inserting prop shaft

prop shaft and reverse gear

adding reverse coil

adding snap ring and gear case cover

forward view of assembly

adding pinion gear

An exploded view of the lower gear case of an electric shift outboard motor.

Parts came in, finished pulling parts

Sorry for the delay on posting.  Gear case came in, need to clean it as there is still some of the forming sand left in it.  Gear oil plus sand equals nothing good.  So it's getting cleaned first.  Had to cut out the forward coil and bearing though.

where the complete cut through ends is where the forward coil started.  Cut both sides of the case and then pried the case up slightly so that the coil and bearing came loose.  Turns out they were corroded in place.

there's the witch of a thing (aka the forward coil) that I was trying to get out with various pullers and slide hammer.

That is the bearing that sits behind the forward coil.

Now onto a game called "What could it be?"  If you remember correctly from a previous post the gear case had damage to it which is why I am rebuilding it.  The bullet cone was broken off so I decided to see what they patched with....  Here's the first picture

What could the metal piece be?  need a hint keep reading.

here's hint two which shows a bit more of what they used to patch with. can you make it out yet?  Ok the last hint is coming your way.

At this point you should be able to see what they used as filler.  If ya need another hint I'm sure there's one either floating around in your pocket or a dish in your house somewhere.  slightly smaller than a penny but worth more.

YES folks they used a dime as filler to patch a hole.  Didn't even weld it in just set it on top and poured what looked like epoxy over top of it.  I've since decided the dime needs to stay on the boat somewhere.

Waiting for parts

So I've gotten the lower unit completely disassembled now I'm waiting for parts to come in.  I scored a bonus and ordered a used gear case from a salvage yard for 150.  They called me today to let me know that due to an error (they pulled a manual shift gear case for me which won't work) I'll be getting a brand spanking new gear case (original quote of 300) for the price of a used case.  BONUS....  also waiting on the seal kit to come in as well, than re-assembly can commence.

After I finish the lower unit overhaul, the next step will be the power head (aka the actual engine) rebuilding the carbs checking the pistons, head gasket, etc.  They really weren't kidding with the joke that BOAT stands for Bring Out Another Thousand. But I love the water and am willing to do the work myself that I'm able to do which will save a bit of money plus I'll know the engine inside and out so if anything happens while out on the water, I'll be able to fix it right then and there.

Gear Case Disassembly

Gear case cover removed

Reverse snap rings you are a devil even with snap ring pliers

reverse coil

ohh look a washer/spacer... damnit all

A look in at the gears before pulling the prop shaft

Prop shaft with reverse gear attached

pitting on prop shaft

Pinion gear with some rust

Forward gear

forward gear top view

The rusted parts on the gears are surface rust only so a scrubby and some parts cleaner should do the trick and bring em back to almost new state.  Still need to remove the forward coil and bearing which the manual states to use a "suitable puller" but doesn't state what....  sigh

Drive shaft and Thrust Bearing removed

Something seems to be missing from this bearing....

drive shaft is pitted around where the thrust bearing sits

silver gob of crap is a horrible patch job for the electric shift cable

removed the silver gob of crap to show the slice through the cable.

The upper and lower gear cases are seperate.

OOOPS guess ill have to repack that bearing.  Atleast I found all the parts.

There sits the lower gear case.  Still need to pull the gears out but ran outta time before work.

Hmmm more of the silver gob crap that they tried to use as a sealant.... what's this metal piece?

Seriously what's this metal piece? it's not listed in my parts manual or repair manual.... oh crap....

As Promised... PICTURES

Two access panels to fish the wires from engine to lower unit for the electric shift.

Success Lower Unit removed and temporarily placed some concrete blocks

Not fully sure what this part is actually used for, but took a picture so that when I reassemble I don't forget where it goes

Exhaust extension pulled and sitting on some cardboard on the ground

Water Pump housing

View inside the water pump housing at the impeller.  Also a reference for the direction of the fins

Another view of the water pump housing

Down to just the gears and seals to pull now.

Lower unit removed

Just a quick update with pictures to come tomorrow.

I've successfully removed the lower unit. Got the exhaust extension off and the water pump as well.

I've put everything that is small and able to be lost into zip lock baggies and labelled the baggies.  I've also taken a ton of pictures of anything I think I might forget how to reassemble.

Starting the maintenance to the engine Part 1

I used the part 1 in the title as I have yet to finish the engine.  Took the battery out and checked the water/acid level and than hooked it up to a trickle charger.  Checked the gas tank and drained what was left out and put a splash of new gas in it and swirled around to clean it out, shined a light in and was shiny.  Bonus.  Mixed some new gas up and hooked the tank back up along with the battery after it sat for 24 hours.  Turned the key and CLICK from the solenoid.

Ok time for some diagnostics.  Checked the connections to the battery and the starter.  Everything was tight, unhooked the light wiring that I had to redo (as stated in previous post PO butchered the wiring for the lights adding various items in)  turned the key and CLICK.  dang.  ok hook that back up.  Called my local junkyard/back yard  mechanic which every small town has, told him I was working on an old boat and engine and needed some help.  within 15mins I heard a loud rumble coming from an exhaust sans muffler.  He jumped out of his car, grabbed his battery, hooked it up, turned the key and the engine tried to come to life.

OK on that note I know feel about 3 inches tall calling him to come down when I forgot the double check the battery after reinstalling it.  Ok so the engine atleast tries to turn over that's a good sign and another bonus.

Pull the vent plug for the lower unit gear oil...... nothing.... hmmm possible not a good thing, pull the drain plug.....  water..... with a small amount of gear oil.....  definitely NOT a good thing.

To the internets I go.  Order a repair manual for my engine as I know this is no longer a simple maintenance job.  This is going to be a total rebuild of the lower unit.  As I sit here typing this the boat is in the bay of one my barns waiting every so patiently for my return once the parts and the manual gets here.

To be continued once items get to house.  Also noted I have gotten this updated to current point.

Scrubbing, and scrubbing, and more scrubbing

Had a few nice days to work on getting the hull cleaned up and to check for any more major damage.  Who knew that the best solution was a scrubby pad and some simply green cleaning solution.  All total took me about 6-8 hours of scrubbing spread across multiple days to get the entire thing clean.  Here she sits at this point.

Finished scrubbing the entire hull and nothing major was found a few minor cracks and chips in the gel coat but nothing substantial thankfully.

Since the weather guessers were predicting rain, the next project was starting to do the maintenance to the engine that god only knows when it was done last.