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Old 04-20-2013
gallilaw gallilaw is offline
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Can't drop gear case to change impeller on Tohatsu 6HP

I need to change the impeller on my 2-year-old Tohatsu 6HP SailPro.

I have the Service Manual and have followed the instructions.

I removed the rubber grommet and loosened the shift rod joint bolt, and the two rods can now move independently and freely.

I have removed the two gear case bolts.

I have tried many times to pull the gear case assembly down to gain access to the water pump, but each time it remains firmly attached, almost as if the drive shaft was bolted to the engine.

I can wiggle the gear cases assembly freely; I just can't get it to drop.

I have used my hand to slam it down, and have tapped it with a hammer, using some wood as a buffer to avoid metal-to-metal contact.

Because my SailPro is a long-shaft, there is a large cast spacer that connect the gear case assembly to the drive shaft housing. I have tried to free up the gear case assembly by disconnecting the bolts that hold the spacer in place. No change; the gear case assembly won't drop.

I have tried turning the engine to move the drive shaft but that doesn't help either.

I am afraid if I hit the gear case assembly any harder I will wreck the motor.

Any advice?
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