What engine and drive is it?

If its an Merc Alpha drive, the throttle must be in FULL forward position.
Else, the lower shift shaft is stuck and the drive won't come off.

Your description/analysis of the sequence of events is somewhat confusing.
If the drive (alpha) is stuck, 2 possible places, the gimbal bearing or the
drive coupler on the engine and its not going to be fun getting it out.

Try posting/looking at http://www.iboats.com/ for help.



"Jason Bourne" wrote in message
...
Greetings:

My friend just had the lower seal in the top half blow out
on his 1990 5.7L Sea Ray. The bottom half came off uneventfully. It
appears
to have been separated before at some time as the impeller and water pump
in general looked like they were brand new out of the box. The top half is
another story. I sort of doubt that it has ever been off the boat. When
the
seal blew and water got in (Chesapeake Bay salt) it made it into the drive
shaft bellows.

I believe the drive shaft splines are corroded to the drive plate.
We can get about 3/16" separation or so between the unit and the bell
housing. I think a little play in the u joints is allowing this to occur.
But pulling on it with more force results in no budge. We pulled using a
winch on the front of his Rubicon Jeep and all it did was pull the Jeep!

So: Has anyone faced this problem before and what did you do about
it? My plan at this point is to cut open the drive shaft bellows and try
to
get some penetrating oil into the area. I can't think of much else. I know
the potential for damage with the "hammer mechanics" approach and am
looking for a finesse method, possibly from someone more experienced.

Thanks in advance for any ideas or help anyone might have.

-Jason