DT85 Cannot Separate Lower Unit

[Diveboy33]

Guys,

Im trying to remove the lower unit from my DT85 1981 model as the casing has split, & replacing it with another I have as managed to get another outboard the same.

Have undone the 9 bolts & disconnected the gear shaft but it still won't budge. Tried hammering a wooden bloc all over the bottom unit to no avail.

Is there something I'm missing or?

Jon

[Solarman]

remove lower unit dt85

Have you disconnected the shift rod?
And make sure there isn't an extra bolt above the prop.

[keakar]

have you removed the trim fin and taken out the bolt underneath it? its the most common overlooked bolt people miss because its way up in there out of sight

[Diveboy33]

Disconnected the shift rod & removed the bolt underneath (forward of the trim fin). 2 nuts & 7 bolts. The spare unit I have has no bolt under the trim fin other than the bolt securing the fin. There is one bolt above the prop forward of the trim vane which has also been removed.

Still stuck firm & hasn't moved a millimetre…..!

[Solarman]

lower unit not coming loose.

From what I see in your parts list of the gear case. It looks like you have 4 threaded studs on each side, and a long bolt that may be under the trim tab or in front of it, and it looks like a short bolt either for the trim tab or through it?

[Diveboy33]

Yes I see all the bolts & have already removed them all from the sides of the casing & the one forward of the trim tab. The trim tab is behind the outboard leg and so does not bolt into the leg.

My guess is that the driveshaft is corroded into the powerhead where the splines enter it.

Unsure if you can get to that bit to lubricate it or free it off while in situ?

May have to take drastic measures & grind off the lower unit as it is scrap anyway. Cant shift it at all. Just will not budge & suspect the last owner did not grease the splines with copper grease when reassembling.

Any more ideas ? Have tapped the lower unit with a rubber mallet & a wood block but to no avail whatsoever.

Jon

[Solarman]

can't separate lower unit?

If the foot is trash, then get a larger hammer. Cutting the foot off won't help much either. You still have to get the shaft out. If there is slightest space in seam try prying both sides at same time you hammer, front of foot then back of foot...over and over till it gives.
It probably isn't the shaft holding the foot, but corrosion holding the seam. Any motor I had a shaft frozen in always gave me over 1/4” drop in the housing when I found out it was a frozen shaft.
Good luck.