I'm hoping for a pointer or two with my Yamaha 9.9 HP high thrust 4 stroke (somewhere 99-01ish, unknown model number).
This engine is on the 21' Fiberform that I purchased a week ago. I know that the previous owner didn't use the kicker much. After getting it home I changed the leg oil. It was definitely old and dirty, but had no traces of water in it. I sealed everything up and it seemed all good. First test on the water was Thursday, which went well. After getting it home and flushing the engine with fresh water I found that the engine wouldn't engage in reverse (although it had perfectly on the water). The throttle would increase but the prop wouldn't turn. Crap! After a bit of investigating I found the new gear oil leaking out as a milky, watery mess from the top vent hole. Double crap! My best assumption was that the sea test loosened things enough that the O ring seals around the gear case were shot. After watching some videos and doing some reading I decided to take the unit apart to inspect. No problems getting the prop off. When I loosened the two bolts holding the gear case on I noticed that I was having to break through factory paint. I guess nobody has been in there in the 20+ years of this engine's life! After freeing these though, I found everything else to be completely stuck. I can't budge the gear unit at all. Again, factory paint all the way around the junction with the leg, which I scored with a utility knife. I inserted a flat head into the tabs on the top and bottom and pried, but to no avail. I tapped all around it with a rubber mallet, which also made no difference.
I saw a Youtube video showing people using a blow torch to free a stuck gear case but I'm trying to avoid extreme techniques like this. Other videos I watched showing removed gear cases don't indicate any trouble doing removal. Any suggestions for how else I might free this up? I'll include a few photos below. Thanks!
This engine is on the 21' Fiberform that I purchased a week ago. I know that the previous owner didn't use the kicker much. After getting it home I changed the leg oil. It was definitely old and dirty, but had no traces of water in it. I sealed everything up and it seemed all good. First test on the water was Thursday, which went well. After getting it home and flushing the engine with fresh water I found that the engine wouldn't engage in reverse (although it had perfectly on the water). The throttle would increase but the prop wouldn't turn. Crap! After a bit of investigating I found the new gear oil leaking out as a milky, watery mess from the top vent hole. Double crap! My best assumption was that the sea test loosened things enough that the O ring seals around the gear case were shot. After watching some videos and doing some reading I decided to take the unit apart to inspect. No problems getting the prop off. When I loosened the two bolts holding the gear case on I noticed that I was having to break through factory paint. I guess nobody has been in there in the 20+ years of this engine's life! After freeing these though, I found everything else to be completely stuck. I can't budge the gear unit at all. Again, factory paint all the way around the junction with the leg, which I scored with a utility knife. I inserted a flat head into the tabs on the top and bottom and pried, but to no avail. I tapped all around it with a rubber mallet, which also made no difference.
I saw a Youtube video showing people using a blow torch to free a stuck gear case but I'm trying to avoid extreme techniques like this. Other videos I watched showing removed gear cases don't indicate any trouble doing removal. Any suggestions for how else I might free this up? I'll include a few photos below. Thanks!
