2018 df200 lower unit removal

[gsmith27]

Chipped cav plate so I need to remove lower unit. I def got all screws out but it will only drop 1/2 inch. It almost feels like the clutch rod is holding it in? Is there something I need to do to disconnect it? It is winter up here so that prob isn’t helping but gear shaft shouldn’t freeze up after one season. Any suggestions?

[briscoe]

If you got that hidden bolt under trim tab (?), the directional plastic blade; it is common to have the gear shifter rod stick to the upper unit. However, yours being a new engine I don't know if that could be.

[gsmith27]

def got the trim tab screw out. i have read about this issue but i agree i didnt expect it with new engine. i guess i'll wait for marina to re open and see what they say. i wanted to get a head start and do it myself.

[wellcraft34]

I’ve seen some older DF225s get totally stuck, to the point of cutting the driveshaft off. Did a new 175 yesterday and had to stand on the cav plate to get it to pop loose.

[Solarman]

Standing on cav plate, not a good move.
most chipped, or broken cav plates can be repaired while still on motor, if taken to a good aluminum welding shop.

Good luck.

[wellcraft34]

Standing on cav plate, not a good move.
most chipped, or broken cav plates can be repaired while still on motor, if taken to a good aluminum welding shop.

Good luck.

ive found that to cause less damage than the other methods when one is jammed tight. And for some reason with a Suzuki, it happens.

[gsmith27]

tks guys. i'll let u know how it turns out. welder off premises and boat is blocked. i'll need it off at some point anyway so prob better to do it now.

[slow530]

there is a second bolt under the trim tab up in the cavity a bit

[gsmith27]

Tks. I got that one. Think of using a hand winch with straps going through the 1/2 inch space

[jHydroman]

I have used plastic wood cutter wedges, they will not damage the mating aluminum surface and you reduce the risk of injury or damage. Use 2 wedges keep the mating surfaces parallel.
Jim

[gsmith27]

tks, Jim. I used wood wedges to get me to where i am now. i'll try that also.

[Murray]

Are you in neutral? Maybe the splines on the drive/shifter shaft are binding at the top. My issue was reassembling, had to give the drive shaft a small wiggle to get the splines to fully seat. I was about 3/4” short from fully seating.

[Moonlighter]

Is this an AP model? Fly by wire?

If so you had better get a service manual because they have some very specific procedures for lower unit removal etc. Can be a real problem if not done right from what Iam told.

[gsmith27]

Yes it is moonlighter. I’ll do that as I haven’t tried again yet. I was waiting for weather to warm up

[gsmith27]

Looks like my initial guess was correct. I grabbed a copy of the service manual and you have to remove the lower starboard side cover and release the clutch rod. Thanks Moonlighter for the advice. Glad i didnt try to force it.