Outboard Wizard Required

[Steve65]

Yes, just unbolt the ones holding the powerhead to the leg, you dont need to remove them all. Some hold the cowl in place

 

[Milgrip]

The attachment (Post 16) is from the official Mercury /Mariner workshop manual dated 2000. Although it is from an earlier model, the assembly procedure is the same.
If the lower unit came apart easily, if you select reverse gear it should go back with a little wiggling .
If you have been forcing the driveshaft into place there may be burrs on the end of the drive shaft preventing the splines marrying up or have you put a large amount of grease on the tip of the driveshaft which is causing a hydraulic lock. The first one I did, I spent a good half hour getting it back together. it really is down to following the correct procedure and perseverance.

 

[Boathook]

Easiest way, sounds a bit drastic is remove powerhead. Then its just gear linkage . Dont worry about water pipe. You can remove that and the grommet then by looking down the leg relocate it into the pump housing. Then replace the powerhead.
You will poss need a base gasket but you will be able to clean some of the waterways

To do that on my malta is a major overhaul. There is no need to that for a 'simple job of changing the waterpump impellor.

 

[LONG_KEELER]

The attachment (Post 16) is from the official Mercury /Mariner workshop manual dated 2000. Although it is from an earlier model, the assembly procedure is the same.
If the lower unit came apart easily, if you select reverse gear it should go back with a little wiggling .
If you have been forcing the driveshaft into place there may be burrs on the end of the drive shaft preventing the splines marrying up or have you put a large amount of grease on the tip of the driveshaft which is causing a hydraulic lock. The first one I did, I spent a good half hour getting it back together. it really is down to following the correct procedure and perseverance.

Just one thing worth mentioning. I had a devil of a job to uncouple the drive shaft from the engine. It was tempting to use taps from a hammer . When inspecting the splines there was no "wet" grease but what looked like caked dirt. It might be worth trying to clean the engine end with a brush on an extension.

 

[Boathook]

Just one thing worth mentioning. I had a devil of a job to uncouple the drive shaft from the engine. It was tempting to use taps from a hammer . When inspecting the splines there was no "wet" grease but what looked like caked dirt. It might be worth trying to clean the engine end with a brush on an extension.

Clean the splines and smear a tiny little bit of water proof grease over them. I also do the same with the bolts holding the drive unit to the leg.