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Author Topic:   CANT REINSTALL LOWER UNIT ON 2000 OPTI

DIVERMAN007 posted 06-02-2009 10:50 PM ET (US)
CAN SOMEONE PLEASE EXPLAIN WHY THERE IS A WHAT LOOKS LIKE A LOSE GUIDE BUSHING OR ROUND WASHER TYPE THING LOSE & BLOCKING MY ABILITY TO GET THE LOWER UNIT BACK UP INTO THE MID SECTION HOUSING.AFTER MESSING W/IT W/A FRIEND FOR AN HR FINALLY I PUT A FLASHLIGHT UP THER & THIS PIECE OF METAL IS IN WAY.I CAN MOVE IT BUT IT WONT STAY IN PLACE UNLESS MAYBE I WAS TOTALLY VERTICAL THEN I CANT PUT UP LOWER UNIT..WHAT TO DO & WHAT IS?PLEASE HELP
aquaholic3720 posted 06-03-2009 10:43 PM ET (US)
Is it possibly the water pump discharge tube that goes from the water pump on the lower unit up to the power head ? Kind of hard to figure this out but I am trying to help using the info you gave. Let me know. jon
sosmerc posted 06-10-2009 12:09 AM ET (US)
I think I know what your problem is. There is a little piece called a "seal carrier" that is supposed to be pressed into the bottom of the crankshaft. The seal is designed to keep water out of the driveshaft/crankshaft mating area when the driveshaft is installed.
I sugguest you buy the carrier so that you can see what you are up against. You can then fashion a tool out of a broomstick or metal rod or something such that you taper the end so that it will slide into the crankshaft and align itself. Then grind a little shelf such that you can tap the carrier back into place. Once you get a close look at the carrier and see how it fits into the crank you will figure out how to make the tool. (you are going to re-install the old carrier, not the new one. If by chance you have already beat the shit out of the old one maybe you will have already gotten it out of the way. Having the carrier in place is not critical...but you should always lube the driveshaft splines before re-installing the lower unit...and it should be pulled for water pump service EVERY year...so it will always be an easy job!
The part number for the carrier should be 54196A6...that may supercede to a later number as I am looking at a 1998 parts manual for 135/150hp Optimax.
Good luck...been there, done that!
tomrz1 posted 06-20-2009 10:29 PM ET (US)
all mercury outboards have to be in forward gear to install

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Author	Topic: CANT REINSTALL LOWER UNIT ON 2000 OPTI
DIVERMAN007	posted 06-02-2009 10:50 PM ET (US) CAN SOMEONE PLEASE EXPLAIN WHY THERE IS A WHAT LOOKS LIKE A LOSE GUIDE BUSHING OR ROUND WASHER TYPE THING LOSE & BLOCKING MY ABILITY TO GET THE LOWER UNIT BACK UP INTO THE MID SECTION HOUSING.AFTER MESSING W/IT W/A FRIEND FOR AN HR FINALLY I PUT A FLASHLIGHT UP THER & THIS PIECE OF METAL IS IN WAY.I CAN MOVE IT BUT IT WONT STAY IN PLACE UNLESS MAYBE I WAS TOTALLY VERTICAL THEN I CANT PUT UP LOWER UNIT..WHAT TO DO & WHAT IS?PLEASE HELP
aquaholic3720	posted 06-03-2009 10:43 PM ET (US) Is it possibly the water pump discharge tube that goes from the water pump on the lower unit up to the power head ? Kind of hard to figure this out but I am trying to help using the info you gave. Let me know. jon
sosmerc	posted 06-10-2009 12:09 AM ET (US) I think I know what your problem is. There is a little piece called a "seal carrier" that is supposed to be pressed into the bottom of the crankshaft. The seal is designed to keep water out of the driveshaft/crankshaft mating area when the driveshaft is installed. I sugguest you buy the carrier so that you can see what you are up against. You can then fashion a tool out of a broomstick or metal rod or something such that you taper the end so that it will slide into the crankshaft and align itself. Then grind a little shelf such that you can tap the carrier back into place. Once you get a close look at the carrier and see how it fits into the crank you will figure out how to make the tool. (you are going to re-install the old carrier, not the new one. If by chance you have already beat the shit out of the old one maybe you will have already gotten it out of the way. Having the carrier in place is not critical...but you should always lube the driveshaft splines before re-installing the lower unit...and it should be pulled for water pump service EVERY year...so it will always be an easy job! The part number for the carrier should be 54196A6...that may supercede to a later number as I am looking at a 1998 parts manual for 135/150hp Optimax. Good luck...been there, done that!
tomrz1	posted 06-20-2009 10:29 PM ET (US) all mercury outboards have to be in forward gear to install