Re: [OMC-Boats] OMC-Boats Digest, Vol 52, Issue 3

I went to my extensive OMG ( oops OMC ) library and figured out that somehow
you have a post 78 upper housing instead of the correct 1970 version as
originally installed. That retainer came with the later models. Could a
wrong match cause a leak? - I know nothing about the later models except
what is in the manuals. The OMC manual says to use special tool 909075 and a
breaker bar as you noted. They also say to use loc tite when assembling it
so no wonder it is a bear to get off. You know you are in for trouble when
the repair manual says to use a breaker bar. If it were mine I would do my
best to get back to the original components - maybe someone would trade an
earlier model housing for yours. I have had the worm gear steering out on my
69 which should be like a 70 and it pops out - maybe too easy and
consequently the redesign. It has the snap ring on the rear and one at the
front for the gear. It looks like your 3/8 threaded cap is boogered up
already. You could drill it out and replace components that are damaged or
you can leave it for the next owner. I can send you OMC service manual data
or parts lists but you already know what is going on now. I could not find
reference to 383544 but suspect that is the ID tag on the gear housing cover
and that cover is probably original to your boat and could be used on any of
the gear housings for 5 bolt caps and later. Maybe hang on to that. You
could trace down the part numbers in the unit and maybe figure if only the
housing was replaced or if other things were also replaced like gears etc.
An interesting problem. I am sure there are older guys out there that know
compatabilities for the various years. I would tackle the bearing housing
later after figuring what to do with the steering gear. Good that you are
doing it this winter when you got time. I personally am working on the bilge
restoration on my 69 sportsman. Waiting for a warm day to paint the bilge
blue. TK
-----Original Message-----
From: omc-boats-request@...
Sent: Sunday, December 18, 2011 12:00 PM
To: omc-boats@...
Subject: OMC-Boats Digest, Vol 52, Issue 3

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Today's Topics:

   1. Upper Unit Worm Gear Steering Disassembly (Ethan Brodsky)

----------------------------------------------------------------------

Message: 1
Date: Sat, 17 Dec 2011 17:08:16 -0600 (CST)
From: Ethan Brodsky <brodskye@...>
To: omc-boats@...
Subject: [OMC-Boats] Upper Unit Worm Gear Steering Disassembly
Message-ID: <alpine.DEB.1.10.1112171621590.10380@...>
Content-Type: TEXT/PLAIN; format=flowed; charset=US-ASCII

I've got a 1970 Evinrude Explorer with the 155 hp V-6 and OMC five-bolt
electric shift sterndrive. I'm in the midst of doing a upper gear seal job
(it's been leaking for years) and am having trouble getting the worm gear
steering shaft out. Has anyone on the list ever done this?

I've got the spur gear off the front and the shaft retainer bracket off the
back, but I can't get the shaft retainer itself out. I've got a couple
close-up photos of it here:
   https://picasaweb.google.com/ethan.brodsky/2012BoatRebuild#5687226168860926066
   https://picasaweb.google.com/ethan.brodsky/2012BoatRebuild#5687226242072410754

The retainer appears to be threaded and has a unusual cap on it
that appears to be meant to be turned with a special tool, which I don't
have. My Clymer manual:
   https://picasaweb.google.com/ethan.brodsky/2012BoatRebuild#5687226897147036882
specifies to remove it using a breaker bar and OMC special tool 909075.
I've tried doing this with a 3/8" open-ended wrench and a hammer, and a 18"
crescent wrench and a hammer, plus the usual penetrating old and torching
on it for a while, but it won't budge. I haven't been able to find the
special tool (presumably a socket) anywhere and I'm inclined just to leave
this as is rather than beating on it until I break something, as it appears
that the seals are both accessible without removing this, as shown in the
SELOC manual here:
   https://picasaweb.google.com/ethan.brodsky/2012BoatRebuild#5687229698798016674
The SELOC manual, which I usually prefer for all repairs, omits nearly the
entire section on servicing the worm gear steering assembly - it appears
they accidentally dropped the text during editing. The figure is from the
1978 and later section, but appears to be correct.

Notable, my OMC dealer service manual (HUFM-19E), which is supposedly
matched exactly to my boat, shows a different retainer assembly:
   https://picasaweb.google.com/ethan.brodsky/2012BoatRebuild#5687226807450069378
that uses two snap rings and no retainer bracket. This seems to imply that
my outdrive is not original, something I have suspected for a long time but
never been sure of. My outdrive is marked "383544: 120-155 hp". Does
anybody know what year that is for?

Also, as long as I'm posting this, has anybody had their upper gearcase
bearing housing assembly apart? It looks like it requires a special tool
to hold the lower spline in place while the upper nut is removed, a press
to remove the old seals, possibly some other special tools for pushing the
new seals in, plus a new nut and some seals and shims. I'm assuming it
wouldn't have to be reshimmed if the same parts were used, so the special
tools for shimming wouldn't be necessary. I've got an automotive seal
installer set that I'm guessing would work and could probably make a tool
to hold the space in place by cutting up my old upper water pump shaft and
welding it to a socket, but I'm thinking this is still not all worth the
trouble. Do the shaft seals in the bearing carrier ever leak? I'll
probably try servicing everything else and reassembling and pressure
testing it before I bother with this.

Ethan

-- 
<a href="http://homepages.cae.wisc.edu/~brodskye/"> Ethan Brodsky </a>
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