1977 115 hp evinrude outboard water pump problem

It sounds like you may be having issues with the shift linkage or the gearcase on your Evinrude 140hp VRO outboard motor.
The sliding leg may be hitting something or getting caught on something as you try to slide it into the housing. This could cause it to go into neutral or prevent it from aligning properly.
Here are some possible steps to troubleshoot the issue:

1. Check for any obstructions or debris that may be blocking the sliding leg from fitting into the housing. Remove any debris if found.
2. Check the shift linkage for any damage or looseness. The linkage connects the shift handle to the transmission and could be causing the issue if it's worn or out of adjustment. Adjust or replace the linkage if necessary.
3. Check the gearcase for any damage or wear. The gearcase contains the gears that drive the propeller, and if it's damaged or worn, it could cause shifting issues. If you suspect the gearcase is damaged, it's best to have a professional mechanic take a look.
4. Lubricate the shift mechanism with marine grease or oil. This can help smooth out any rough spots and make it easier to shift.

If none of these steps resolve the issue, it may be best to have a professional mechanic take a look at your outboard motor to diagnose and repair the problem.

Like any other outboard you have to drop the gearcase. The big concern is it is electric shift cable that runs down to the gearcase. You have to attach a wire to it after you disconnect it so you have a way to pull the cable back up after you finish the repair.

It may look easy in the book but there are a few things that can go out. Such as the key/roll pin that drives the impeller can slip out on assembly. Water tube out of hole or damaged OR pieces of old impeller in it depending on why you needed to replace it. There are more but if you are not a trained tech it may be time to find one.

Look below lower mountings you will see the shift rod with along nut and a lock nut,undo long nut,do this with motor in reverse gear,some 40s have a stainless plate cover which you have to remove first

Take the cowling off. Also drop the foot. There wil be a stainless linkage rod that runs the length of the motor that you will have undo to drop the foot. The water impeller will be inside a stainless casing that you will have to disassemble.

Line up the water pump housing with the drive splines and look straight down on it all -there will be a clearance cast in the pump housing some where. It's a matter of perspective. Or you have the wrong pump.

Okay this is on total memory. The shift shaft for a lot of those engines goes right up through the pilot shaft and exits just in front of the block under the carburetor(s). You will see the **** linkage arm connected to this shaft sometimes it's double nutted. See if you can slide the lower unit back up to the housing and put a bolt in it to hold then undue the shift shaft linkage, Remove the bolt and drop the lower unit. Be careful of the water tubes and check make sure the rubber grommets are in place in the pump housing not on the tubes. Clean up the pump housing and install the new impeller kit.
Put the impeller down the shaft on top of the impeller plate, lightly grease the inside of the housing the impeller plate and impeller. Then lower the pump housing down to the impeller while turning the drive shaft clockwise lightly push down on the impeller housing. This will fold the impeller blades all in the correct position and provide lubrication to the pump until the water gets into the pump. To make life easier re-grease the drive shaft spline and the water tube grommets this will ad ease in reinstalling the lower unit. be careful to make sure you thread the drive shaft, water tubes and shift shaft all in at the same time. After installation you may find you need to adjust the **** linkage.

This is a long shaft, should disconnect just below carburetor. Pull all the way out of mid section.

Put engine in fwd gear. Then disconnect the shift linkage. Remove the bolts that hold the gearcase on and slide gearcase off of the tower. Remove the 4 bolts or screws in the waterpump housing and lift the housong off. Replace the impeller and reassemble in reverse order. Make sure that you get the water tube lined back up and you can twist the prop to line the splines back up in the powerhead.

goto local library get book on unit!!! :)