Help Quick Gearbox/engine Problem Yamaha 55hp!!!

[EllWilcox]

hello can anyone help?

I have a fully workin yam 55 gearbox for a yam 55 engine. (YAM 55BE). right i am just about too put the new gear box on to the engine, though one minor problem. On the gear box i have noticed 2 little metal like sugs one at the back of the box an one at the front they stick up and i believe they are used to line up the gear box with the engine before bolting it on. The problem is the engine has these little metal sugs in the same place too, so therefore when joining the box an engine together these stop it?? What shall i do?? they dont look like they unscrew or pull out. so was going to saw them off then just bolt the gear box together?? is this ok to do? will it make a difference to the engine???


thanks

[EllWilcox]

sorry not sugs wrong word haha i was thinkin of --- lugs

[spartacus]

Ideally you would have wanted the mid section to match up with the gear box. The raised pins help 'locate' the two sections prior to bolting together. It should be okay to hacksaw them off (might be possible to drill new holes) and file down to a level surface. One word of caution - as the pins will no longer be there, hand tighten the bolts individually. Once you're happy with the allignment - fully tighten them to the recommended torque setting.

[EllWilcox]

i was thinking about the drill idea?? but do you think it might crack the casing??

Thanks for the help

[Downhilldai]

Are you sure these 'dowels' aren't removable?

[Nos4r2]

Originally Posted by Downhilldai

Are you sure these 'dowels' aren't removable?

They are removable.

[EllWilcox]

what is the best way to remove??

[jwalker]

There isn't a best way. They will be steel into aluminium so if there's corrosion they're likely to be stuck firmly in place. However, my first shot would be to look on the outside of the lower unit to see whether the holes they are fitted into pass right through so that they can be drifted from the outside. If not, grip them tightly using a vice grip wrench and attempt to rotate them. If they move, you will be able to pull upwards while rotating the pin and it should work free. If, say, the ones in the lower unit are stuck try removing the ones in the leg - you may be lucky. If they all appear stuck, you've got a few options. My first would be a gentle tap sideways on the pins along with something which will sneak down any space to lubricate the pin withing the casing - oil, diesel, white spirit or WD40 would all be suitable. Applying heat may also help.

If they a well and truly stuck you may be able to carefully mark the casing on the outside and drill a hole to allow a drift to be used to drive them out. If you do this, be sure to support the area close around the pins while hammering the drift. If all fails, drill them out and replace them with new ones.

Good luck.