1998 Mercury 200 EFI Mechanical Damage Rebuild

[Bigwrench]

Rick, I have the Pex tools buddy. The fancy crimper and the removal tool. I can run them down tomorrow evening if you want them.

Thanks buddy , I have the crimping tools for these clamps just didn't have them here at the house. Never thought of using the PEX ones either but that would work I bet for sure.

[Oldfart9999]

Lip, we need a pic of a clock doing a countdown. Lot of work, thought head scratching and paying to detail there, Kudos Rick!!
Rodney

[Lipripper]

Lip, we need a pic of a clock doing a countdown. Lot of work, thought head scratching and paying to detail there, Kudos Rick!!
Rodney

All my clocks are busted.

[Bigwrench]

All my clocks are busted.

My problem is the clock more than anything LOL   I cant seem to find the time to work on it but in spurts here and there ! I may have to skip baseball practice one night or something. Supposed to be big storms moving in this afternoon, If that happens baseball will be cancelled and ill back it back in the garage and get to work on it !

[Bigwrench]

Anyone ready to finish the beast up ? Let's get it on !!!

[Lipripper]

Anyone ready to finish the beast up ? Let's get it on !!!

No ball game tonight. get er done then.

[Bigwrench]

Ok here we go with what may well be the final post of this thread .... Does it turn out good or did it all fly apart and I decide to set a match to it ? Hmmm stay tuned and find out LOL

Time to install the water pump and the lower unit
I lubricated the water pump housing with that GM Super Lube I like so much

Inserted my new impeller and made sure the fins were going in the same direction as the old one

There is a notch inside of the impeller that lines up with this key

The flat side of the key sits against the drive shaft in the flat location here


I used the same lube to stick the keyway to the shaft location

Making sure my gasket was in place I slowly slid the pump housing down the shaft

Turning the shaft until the keyway lined up and it set flush against the lower unit

Tightened the nuts and 1 screw and installed the water pump connector

It is now ready to be installed to the powerhead.
Hooked up the battery and trimmed the motor up

[Bigwrench]

Installing the lower unit to the powerhead can be tricky and there are several things that have to line up at the same time ,
The water pump connector tube
The shift shaft
The speedometer rubber tube and of course the main driveshaft
I had to do this all by myself and it was sorta tricky and no way I could catch photos of it.  I just took it slow and eased it all up until the very front stud was sticking up high enough to get a nut and washer started on here

Once that nut was started it will hold it all in place while you start the other nuts and connect your water hose up.


Slowly tighten all nuts evenly until it's fully seated flush


Momma_wrench came home about the time I was tightening up the last few nuts and installing the trim tab



And that's pretty much it folks , been a long drawn out , expensive process.  And if I had to do it all over again to be honest I'm not sure I would thanks for following along and hope this has helped at least a few people . Showed some trials and tribulations and taught myself a few things in the process.  THE END !!!

[jprism]

Great read thanks for all the work and pics that allowed us to follow along. Followed your video last week and replaced my wheel bearings, oil seals and installed new oil hubs.


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[Bigwrench]

Great read thanks for all the work and pics that allowed us to follow along. Followed your video last week and replaced my wheel bearings, oil seals and installed new oil hubs.


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That's absolutely awesome ! I'm glad someone was able to benefit from that one !!!

[Bigwrench]

Was a fun experience overall , if I had more free time it would have been better where I could stay on it and do it all in a weekend inside the garage. Getting on it for a couple hours and then a couple weeks in between was hurting me lol

[jprism]

What no startup?


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[Bigwrench]

What no startup?


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I was wondering if anyone would catch on to the fact that I didn't say anything about how it ran or didn't run .... LOL
Messing with ya.
Bled the air out of the fuel system while momma pumped the bulb. I then gravity bled the oil pump.
We hooked up the muffs and I let Holston_Slayer do the honors and after cranking it for a couple minutes the warning was going off , the warning buzzer didn't register with me lol. Grayson kept asking me what that was lol. After checking to find I had no spark I realized the kill switch was out of the boat and we flipped it to the closed  position and this is what happened (gonna try this directly and see if it works , if not I'll have to try a different way tomorrow). 

[Bigwrench]

Anyone notice anything strange from the video ?

[hughesjasonk]

Anyone notice anything strange from the video ?

Sounds like it's running pretty good to me

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[Donald Garner]

Really didn't notice anything really wrong except the water pressure was kinda low it looked like.  I noticed you kept sticking your hand under it.  When the RPMs got up the pressure seem to be stronger.

BTW you did a great job sharing the pictures and instructions on the rebuild.  I hope she runs strong for ya.

[Bigwrench]

Sounds like it's running pretty good to me

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Yep real good but I have no forward or reverse gears.
I am pretty sure the shift shaft just pushed the connecting tube up and didn't spline up. Or missed it entirely . I'll have to drop the lower unit most likely to check for sure. Will do that tomorrow lol. For now I'm just glad it is running !


I know there is a procedure in the manual for linking that shaft up but I failed to read the manual first lol. Got ahead of myself.

[cojab]

Anyone notice anything strange from the video ?

No celebratory beer??

[merc1997]

Yep real good but I have no forward or reverse gears.
I am pretty sure the shift shaft just pushed the connecting tube up and didn't spline up. Or missed it entirely . I'll have to drop the lower unit most likely to check for sure. Will do that tomorrow lol. For now I'm just glad it is running !


I know there is a procedure in the manual for linking that shaft up but I failed to read the manual first lol. Got ahead of myself.

yep rick, sometimes you have to reach in with a long pair of needle nose and tweak the shift shaft to get it to line up.  great job, and i knew it was something that you could do, and you will have a brand new engine, that in my mind will be better than it was to begin with.  we built a few thousand engines over the years in our machine shop, and never did have one come back.  you did a great job, and i can tell you that you would have been welcome to have worked for us.

bo

[merc1997]

forgot to add to be sure to check your timing.

bo

[Princeton_Man]

AWESOME Buddy!!

[Pferox]

Great Job Rick!

On the Video quality question, did you know that each time you transfer a video it is processed, and usually made smaller to text? One reason that I always upload to YouTube via WiFi or HardWire, and never try to use texted gigglebyteage unless I have to.

[Bud Kennedy]

Rick, I just cannot state enough superlatives to describe your effort.  The quality of the posts that took a lot of work coupled with just wonderful step by step detail is absolutely one of the best things I have ever seen anywhere.  Your mechanical skills are just top notch and reflective of your character. 

Your posts have received over 7000 views and indicate that you had a lot of brothers following you through this process.  We cannot thank you enough for sharing all of this with us.

[jprism]

Great job Rick you are indeed very gifted. I did notice one thing from the video your hair on top might have been caught in the flywheel


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[Oldfart9999]

Yep real good but I have no forward or reverse gears.
I am pretty sure the shift shaft just pushed the connecting tube up and didn't spline up. Or missed it entirely . I'll have to drop the lower unit most likely to check for sure. Will do that tomorrow lol. For now I'm just glad it is running !


I know there is a procedure in the manual for linking that shaft up but I failed to read the manual first lol. Got ahead of myself.

Couldn't see you trying to shift , was wondering why you weren't putting it in gear. Like Bo said, great job and you have a new or better than new motor. Downside, can't buy that new Ranger now.
Great job! Now, back to smallblock chevys.......
Rodney