Lower unit - 2005 Mercury 9.9hp -

[brianmtsinc]

I removed the lower unit on my 2005 Mercury 9.9 to replace the impeller. It seemed easy enough.  I am NOT a mechanic by any means. In fact, I am beginning to think I should not have attempted this..... 

I removed the 4 bolts on the bottom and then the 1 bolt holding on the shift linkage and bushing - only accessible after dropping the lower unit a few inches. To the surprise of many, I replaced the impeller without issue, but now cannot get the lower unit back on. The issue seems to be the linkage and I am wondering if I screwed up by removing it where I did OR if I just need to keep working at it?? I am worried that I may bend the linkage if I push any harder.

Any help is greatly appreciated!!
THANK YOU!!
Brian

[206]

Last spring, I went for it just like you on a yami 15hp.  Make sure it's in neutral.  I kind of remember the same problem you are having.  I don't think you gears are lining up.  Take it out, turn the prop a little bit and try again.  I remember it is kind of tight the last little push and was relieved when it went in all the way.

I was unfortunate enough to have to do it two times in a week.  The rubber O ring didn't come with my kit and I took a gamble of buying one and replacing that the second time.  Pissin good.

Keep trying.  You didn't hurt a thing.

[DIYARCHERYJUNKIE]

Yeah the prop position and the gears being in neutral.  I remember it getting stuck then it will slide in when you free up the gear.

[brianmtsinc]

Thanks!  I am not sure I had it in neutral - I will run out and try that now