Join Date: Jul 2007
Location: Truckee, CA
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Re: Can't drop gear case to change impeller on Tohatsu 6HP
Finally got it apart. It took an unbelievable amount of force. I actually snapped a pry bar. Used a heavier pry bar, applied more force than I want to remember, and the drive shaft finally released. Put in a whole pump repair kit, not just the impeller.
After all the time and effort getting it apart, I forgot to care about the gear sync when I put it back together. Now all the parts are assembled and I don't know what direction the clutch cam is pointing, what gear it's in currently, or whether the cam rod and the shift rod are properly set up at the shift rod joint.
Oh, dear!!, if you took the drive shaft out of the gear box you may have a problem. My experience was with OMC motors, so have no hands on experience with the Tohatsu. You might try gripping the shift rod and push it as far down as it will go. Then pull the engine over to see which way the prop turns. Then adjust the shift lever accordingly.