Guys,
i ended up buying a PD that is need of a powerhead rebuild. I've read all the other post about how difficult the removal is because of the clutch being froze on the shaft. I underestimated the frozen shaft.

I have all externals unhooked and 4 main bolts removed. there is a heavy plate that separates the powerhead and the clutch. I can pry between the powerhead and that heavy plate and all it does it move the shaft and clutch as one up and down about 1". I'm on my second night of soaking with the PN Blaster penetrating oil. I've soaked everything visible.

I'm concerned about prying too much against the bottom of the motor as im sure that casting will break at some point. I thought about hooking one of our forklifts to it and just take slack out of a chain with slight tension and then start tapping around. Any help or thoughts would be appreciated.
Thanks
Lectric

You have to lift the powerhead off the lower unit, drop the spline adapter, and remove the bolt holding the clutch onto the crankshaft. Hopefully you have done that already, but from your post, it doesn't look like you did. Post a pic of what you have done so far.

put those bolts back in. Undo the 4 large bolts that hold the two big plates together. Lift the motor up via engine lift or fork lift. remove the spline adapter from the shaft. remove the clutch from the shaft. finally undo the 4 bolts that connect the plate to the engine.

I think thats right.

Yea it sounds like your trying to do this bass ackwards.

yep,
no wonder the damn thing wont come loose. I've been doing it all wrong from you have above owen and cb.
I'll resecure and try again tomorrow.
Thanks
Lectric

Looks like you have a LOOOOOOONNNNGGGG road ahead of you. You didn't happen to snag a gatortail boat with that motor did you?

Cb, thought you might be asking that b4 too long. You'd be right. I'm going to give it go... Since I know nothing about a PD it's obviously not startin out too good but i like a project. Between th harley shop across the street, Cody at SETX who's been extremely helpful, my mechanic at work, and my typing ability, i hope to get her back going

Sonofabitch! Good luck with it. Be patient and try to figure out disassembly/reassembly procedures before you start tearing shit up. Don't want it to cost any more than it needs to, to get it back together.

Just posting and update with a question. Finally got the damn engine and clutch off!!!!!
Son of a ........

Put the four motor bolts back in, took out the 4 large motor/clutch bolts,ran a strap under the motor, put tension on strap, and slowly got the engine, tiller, and complete clutch assembly out of the out drive.

I finally accessed the bolt at the bottom of the motor shaft that holds the clutch on. Once that came off, the clutch almost fell off. I guess all that penetrating oil from last week helped. then unbolted motor from tiller assembly with the four original bolts.

My question is that there is a slot on the motor shaft that would indicate some type of key way? only thing is when all this was coming apart i didn't notice any key. did i miss something?

Na, you're good.

there is a key built in the clutch.

Is there anything i need to do to the outdrive maintanence wise while the motor and clutch is out?
Im going to replace the oil and re-grease but that was all i had on my schedule.

took my flashlight and looked down into outdrive and it looked a little dirty with grease but nothing out of the ordinary.

is it manual reverse?

yep, manual reverse with hydro trim.

there is a plastic collar right above the knuckle in the LU. It is where the tension knob is for reverse. I am not sure how often you are supposed to change(probably depends on how much you use reverse) but it probably wouldn't hurt to change it.

thanks ddb,
I'll take a look at that tomorrow. Gonna start the motor tear down this week.
I'm sure i'm going to be flush with questions on this one.

just remember to remember how you took it apart

Lectric. U happen to be in NE Ar? Just curious. We stayed in a house they called the Lectric duck Lodge a few times when hunting sky carp