The totally stuck drive shaft problem

[joecb]

Trying to help a friend pull the lower unit. So far tried all the usual “suspects” … tapping, hammering, wedges, soaking penetrant, no luck. The motor apparently did see some salt water at one time in its life, never a good thing. So, we are down to one last fix that I have heard used in a case like this… loosen the tower to powerhead screws and shim one side, start the motor. The angular mis- alignment works the drive shaft spline loose from the crankshaft socket. Anyone have any experience with this approach?

I’m afraid that the ultimate solution, involves a hacksaw.

Joe B

[fleetwin]

OK, so I am assuming you are referring to the long shaft 9.5hp in the other post, correct?    If so, you could surely try running it with the driveshaft out of alignment, nothing to lose.

If not, I would try to get in there with a chisel, or air chisel and bust up the aluminum impeller housing to release the driveshaft key from being jammed against the top of the aluminum housing, which will allow the gearcase to come down without damaging the gearcase/extension housings.  Once the gearcase is down, the next chapter is figuring out how to get that driveshaft out without damaging it.  It could be tough finding a long driveshaft for a 9.5hp, although I’m pretty sure I do have one.  Will gladly donate it if needed…

He will need to find a new shift rod boot/seal as well…

[joecb]

Yes you are correct on the source of the story. I expect to have “hands- on” look in a couple of days. Will keep you posted. Depending on what I see, may be better to go with standard length set-up anyway.

Joe B

[elgin2]

I used a slide hammer with vise grips on the end. Clamp above where the drive pin for the impeller goes. Soak with Kroil or similar fluids prior.

[fleetwin]

Well, the extension housing may be a blessing in this case.  Removing the extension housing once the gearcase is down will allow easy access to the driveshaft above the water pump so you can clamp/use pullers, etc without worrying about damage in the seal/bushing area.

[joecb]

That’s what I’m thinking, Don.  Sacrifice the extension and convert to standard.  Standard shaft should be readily available.

Joe B

[fleetwin]

Yes, I have seen plenty of short shaft driveshafts online for this model.

[joecb]

checking around on line it looks like we’ll also need a shorter (standard length)  shift rod , I think its part 0309582. the short drive shaft is 0309640. Much appreciate if someone could verify those numbers for 1964 Evinrude 9.5 hp

Thanks,

Joe B

[fleetwin]

I come up with 309628 for the longer shift rod.  309582 is the standard/shorter shift rod.  Once the gearcase is off, you may be able to just cut 5″ off the lower shift rod without disassembling the gearcase.

Keep in mind, you/he will have to find a new shift rod seal:

Evinrude Lower Unit Group Parts for 1964 9.5hp 9422S Outboard Motor (marineengine.com)

#78

Finding this could be tough.

[Author]

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