TOPIC: Shift Rod "O" Ring replacement, 25HP 1963 Gale

I need to replace my shift rod "o" ring and I've tried six ways to sunday on how to get it out and I'm at a loss for ideas. It's pressed in differently than most other gearcases making it difficult to pop the bushing out. Is there any secret, or method to popping the bushing out as mine presses in from the bottom (skeg side) and can only be pressed out from the top (powerhead side) see the picture 55, 56 and 60 are how this motors bushing and o ring are done..

Frank Robb with the AOMCI makes a tool that makes changing the parts a snap

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Failing the special tool, take a 5/16-NF tap and tap threads into the bushing.

Then you can thread in a bolt and use that with a slide hammer.

I've also drilled a clearance hole in a stout piece of angle or flat bar, then laid that across the flat surface of the lower unit, threading the bolt thru the puller bar into the bushing. The fine threads provide a lot more leverage and as you tighten the bolt, it'll pull that bushing right out.

Then you use the same bolt or a longer one as you see fit, as the bushing's installation tool. Just thread the bushing on the end and tap 'er back into place. I clean things up real good, then spread a thin layer of Permatex #3 Aviation-type gasket dressing on the bushing, to prevent salt buildup.

Note that if you get a pretty good 'reef' on the bushing and it doesn't want to bust loose, a judicial application of heat to the gearcase, right where the bushing sits, should break 'er free.

It's much easier to pull bushings that are pressed in from above, but I've used this method on many of the type pressed in from below. Cutting threads into the bushing hasn't ever seemed to have any deleterious effect, either. Still plenty of bearing surface left.

One last thought, be sure you scrape out any deposits in the bushing cavity before reassembling. Salt & crud gets in there and will bind things up.

HTH & G'luck with the repairs.........ed

I bought one of Frank's tools for the same job on my '58 Sea Horse(s). It was absolutely worth it.

Best of luck,
Rob