More Motor Repair Questions: Pulling Gearcase Cover?

[Carl]

I knew when I got this motor for $100 I was going to have to replace the gearcase cover. The "ears" where the bolts go thru into the lower unit are broken.
Bought a used lower unit without drive shaft, prop or water pump kit, but otherwise in good shape, this morning.
The used parts guy I bought it from recommended adding my drive shaft & water pump kit & prop to the lower unit he sold me, vs. trying to remove the good gearcase cover and moving it over to my existing lower unit. He said the ears are notorious for breaking when trying to remove the cover. And this way, I dont risk messing up the seals, which appear to be good on the one he sold me.
Ayyone out there have experience with this repair?
How hard is it to move the drive shaft from one lower unit to another?
Any thoughts from the brain trust??

 

[Ed L.]

I knew when I got this motor for $100 I was going to have to replace the gearcase cover. The "ears" where the bolts go thru into the lower unit are broken.
Bought a used lower unit without drive shaft, prop or water pump kit, but otherwise in good shape, this morning.
The used parts guy I bought it from recommended adding my drive shaft & water pump kit & prop to the lower unit he sold me, vs. trying to remove the good gearcase cover and moving it over to my existing lower unit. He said the ears are notorious for breaking when trying to remove the cover. And this way, I dont risk messing up the seals, which appear to be good on the one he sold me.
Ayyone out there have experience with this repair?
How hard is it to move the drive shaft from one lower unit to another?
Any thoughts from the brain trust??

This is where YouTube is your friend. Lots of videos on replacing the water pump in your engine. They will explain removing the drive shaft and reassembly. It's been years since I've had a 9.9 but as I recall it's a pretty simple repair. The driveshaft isn't a problem but as I recall take some measurements of the shift shaft collar. The shift rod is 2 part when disassembling and reassembling the lower unit and upper shift handle need to be in the same position when reassembling so it doesn't bind as you reassemble the lower unit. Don't try to use the bolts to get lower unit in place. That's how the ears get damaged. Good luck. Those are good little motors.

 

[Huntindave McCann]

How hard is it to move the drive shaft from one lower unit to another?

Removing the driveshaft from the lower unit, would be the next step, following complete removal of the water pump. Most folks just replace the impeller and never disturb the lower plate of the water pump.
The drive shaft should just slide right up out of the lower unit. I say that based on the parts diagrams. Yes, I have removed a drive shaft. Once, when I swapped shafts during a long shaft to short shaft conversion, years and years ago.

Best advice I can give you is inspect your driveshaft for any nicks before installing it into the good lower unit. Grease it up well, so it slides into and thru the seals and bearings situated below the water pump. Grease the seals too. Replacing those seals and in particular the bearing is a PITA requiring special tools.
Replacing ONLY the shaft should be a cakewalk.
Hopefully the seals are good in you "new" lower unit. If after it's all reassembled and on the water, you find different, then you can consider swapping the gearcase cover over to your old lower unit and reassembling the drive shaft back into your old unit.

Ed is talking about the ears on the lower unit flange breaking, not the ears on the gearcase cover. However the same thing applies. Make sure to cleanup any corrosion. The gearcase cover needs to be free to slide in place without resistance. The bolts are there only to hold it in place, not drawn it into place.

 

[Carl]

Thanks!!
I just watched a video on removing and cleaning the carb. Seems easy except for keeping the pull start assembly from exploding!!
I’ll order a carb kit and an impeller kit. Might order a new fuel pump too just in case.
Any thoughts on an inline fuel filter??

 

[Huntindave McCann]

Any thoughts on an inline fuel filter??

I've never used one on that size motor. My 25's have always had a factory inline sediment bowl and filter. I suspect the reason for lack of a filter is maybe just space requirements under the cowling. Not sure how much restriction installing a filter might add to the load on the fuel pump built into a 9.9 motor.