Caille Neptune gear case disassembly

[Buccaneer]

I’m trying to get the shafts and gears out of the gear case,
and not even sure I’m proceeding correctly.
The “top” driveshaft gear, which you’d think would have
to come out first, will not, as it’s pinned to the driveshaft,
and one cannot drop the gear and shaft into the case to
access the pin, with the prop shaft gear in place..
I removed the thrust adjustment plug in the front of the case,
thinking that it would drop the prop shaft and gear enough
to allow the drive shaft and gear to drop down to remove the pin,
but it does not.
Therefore, I removed the “stop pin?” in the prop shaft, and I
am attempting to drive the prop shaft out the front of the case
through the prop shaft gear and water pump cam.
I’m only able to drive the shaft about 1/8″ down and it doesn’t
want to budge anymore.
Is the water pump cam lobe and prop shaft gear “one piece”, or
two pieces, and is their possible another pin in the cam lobe
that I can’t see?
Anyone recollect how I should proceed before I break something?
Thanks

Prepare to be boarded!

[Tom]

It looks like you need to unscrew the gear lash adjustment screw in the front of the gearcase, then push the propshaft out the front. With that out of the way, remove the gear. Then drop the driveshaft and pinion gear to remove the pin on that gear. If you’ve hammered on the propshaft at all, it may not pass through the gear on that shaft.

T

[Tubs]

A "Boathouse Repair" is one that done without having tools or the skills to do it properly.

[Buccaneer]

Tom wrote:

It looks like you need to unscrew the gear lash adjustment screw in the front of the gearcase, then push the propshaft out the front. With that out of the way, remove the gear. Then drop the driveshaft and pinion gear to remove the pin on that gear. If you’ve hammered on the propshaft at all, it may not pass through the gear on that shaft.

T

Tom, what you describe is exactly what I was trying to do.
I took the Dremel and polished around the pin hole in the
prop shaft in case the shaft was hanging up on burrs there.
Hopefully a new day tomorrow brings fresh light to the problem..
Thanks!

Prepare to be boarded!

[Buccaneer]

Tubs wrote:

Tubs, pretty sure I don’t have a set screw like you show, but
I kept looking for things “hidden”.
Guess if it went together, it’s got to come apart!
Thanks.

Prepare to be boarded!

[PM T2]

For lower units like yours, I recommend getting a tool made that will do the job. I machine a piece of brass that threads into the nose of the gear housing, then I drill & tap that piece all the way thru to accept a 1/2″ bolt. This gives you a removal tool that pushes on the front end of the propshaft without beating on it. You use the bolt to push the prop shaft out the back, since its a lot less distance for the shaft to travel instead of coming out the front. It might help to grind a slight point on the 1/2″ bolt to keep it centred on the end of the shaft.

Some Cailles do have the water pump eccentric as a separate piece from the gear, but they are keyed to the shaft instead of being pinned.

Hope it helps.

Best,
PM T2

He's livin' in his own private Idaho..... I hope to go out quietly in my sleep, like my grand-dad did..... and not screaming, like the passengers in his car...

[Tom]

Yeah, Chris’ plan makes a lot more sense. Keep us posted…

T

[Buccaneer]

PMT2, Thanks for the idea.
I suppose I should put the gear case cover
on after I made said tool, to keep the prop shaft aligned and hold
down the prop shaft gear, to keep it from pushing on the drive shaft
gear, etc.
Will let you know how it goes!

Prepare to be boarded!

• This reply was modified 4 years, 6 months ago by Buccaneer.
• This reply was modified 4 years, 6 months ago by Buccaneer.

[Buccaneer]

Well, I got the gear case mostly apart, but it’s been a “bitter sweet” day, lol.
I spent half the day and made a Caille special drive shaft removal tool,
to screw into the front of the gear case. The hole in the front of the gear case
is near a 15/16″ x 18 tpi thread. I got the OD of the tool the same as the plug,
but for the life of me, could not get the tool started in the hole.
Guess I should post to the “lathe forum”!
Anyway, I came up with “Plan B”, and used the original front case plug,
and found a brass ball / bearing about 5/8″ diameter, and put under
the plug, on the prop shaft, to drive out the shaft.
It started moving the shaft as the brass punch and hammer method did,
then stopped in about 1/8″.
Much to my dismay, a screw slot magically appeared in the cam lobe as I was looking
in the water pump hole. (How does this happen?)
Anyway, I was lucky enough to get the threaded pin out….. albeit in two pieces.
The pin portion that goes into the prop shaft about 1/4″ was broken off.
After that, the brass ball and plug did the trick to press the prop shaft out
of the gear / cam lobe assembly.

The hole in the inside of the gear case plug that the prop shaft goes into, is
worn big time, and looks like someone attempted to tighten it up with solder
at one time. Hopefully I can put a repair bushing in this…… or make a new
plug that fits the shaft, If I can figure out why my special tool didn’t fit.

I still want to remove the drive shaft gear from the drive shaft, and will
attempt removing that pin tomorrow…….. at least now the pin is accessible.

Prepare to be boarded!

[Author]

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