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How do I separate a stuck lower unit on a 1984 25hp Evinrude?

I bought a boat with a 25hp Evinrude that appears to have not been maintained. I want to replace the water pump and maybe some other seals, but cannot get it to drop. I've squirted PB Blaster on the main bolt for weeks and still not budging. Hitting it with large rubber mallet is getting me nowhere. Saw a YouTube where the guy stood his motor upside down and pumped an entire can of degreaser into the housing to free up a stuck drive shaft spline. I also had a guy tell me that I needed to heat the bolt area really hot, but I only have a propane torch, no acetylene. Any ideas?

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IF IT DROPPED PERHAPS 1/2 INCH THE SHIFT ROD NEEDS DISCONNECTED .

Posted on Nov 30, 2019

  • nw_zfan Nov 30, 2019

    Thanks for the tip. It has only separated enough to maybe slip a razor blade in. This is only at the front (away from the main bolt). I did remove the small bolt from the shift rod coupler. It is a long shaft. Should I be trying to separate at the top the "extension" section, or just the lower part? i have removed all 8 bolts holding both sections together. It does seem that the main bolt with the nut on top has not moved at all. Still squirting a few drops of PB Blaster on the threads to soak down in any time I walk by the motor. Very frustrating.

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Posted on Jan 02, 2017

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SOURCE: 1975 75 hp evinrude water in lower unit

You could take off the lower unit and leave the boat home. All they need is the bottom. The propshaft seal can be cut from fishing line. There should be another seal on the shift assembly and a third on the powershaft. Some you could do, but the shop can pressure test before and replace only what you need. Then pressure test after the repair to verify it seals.

Posted on Jul 20, 2009

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