TOPIC: 1986 6HP Evinrude

I attempted to tear down my Evinrude kicker. E6RCEC = model #
The unit became stuck in FWD. The biggest problem now is that the prop shaft is stuck to the FWD gear via the clutch. It cannot be removed because the pinion gear is in the way. Any suggestions?
I think I need to somehow hold the fwd gear in while pulling the prop shaft off and not damage anything?

The l/u oil looked good. Gears all look good.
No water in there. No metal shavings.

I am having a hard time visualizing how the dog can be stuck to FWD gear. You have disconnected the shift linkage?

Thanks for the reply.
Yes pretty much everything is out, except the propshaft which is stuck to the fwd gear, and the pinion gear which won't drop free unless the fwd gear and prop shaft are out of the way.
This is sort of a catch 22.

I tried very hard before tearing this down to get it into neutral. It would not budge.

It just happened this past week on vacation. It would go to rev and neutral fine. Push the lever fwd and nothing for a few seconds, then it would slam into fwd. The second time we left it in fwd, and we used the engine the rest of vacation that way.

Lower unit fluid looked fine, no water, no shavings.
Gears all still look good.

That motor has a Mercury-esque shift arrangement with a cam at the front of the propshaft. Have you tried removing the top plastic cap and then pulling the shift rod? It's held in place by a circlip under the cap. I am assuming the driveshaft is already removed?

If that's all done, I would clamp the propshaft in wood blocks in a vice and GENTLY tap the housing with a wood block to try to pull the propshaft out. I suspect the bearing in the forward gear has worn to the point where it is ridged on the propshaft or has seized entirely. Gentle brute force to get it apart. I have some innards parts for those units if needed...

Yes there is a cam at the front.
Shift rod is out. I easily put it back to see how it all worked.
I can't use force because of the pinion gear. That is what prevents the rest from coming out. If that is all that gets ruined not too bad. As long as I don't damage the housing.
I will gets some pics up soon so you can see it yourself.



The drive shaft is out as well as everything else.

Correction, it is a 1989.
No clutch dog.
4 detent ball are there.
Rear two are out.
Front two are likely part of the problem.
That and the plunger.

OK, got it out. F-I-L had the winning idea. I found an old screw driver, put it through the prop pin hole, and hammered outward with the help of a long chisel. 6-8 medium whacks and out it was.

Lost one of the drive balls, other was sheared in 1/2. It looks like the root cause was a worn shifter pin, or weak spring. Then the last slam into fwd did the real damage. Minor marks on prop shaft, and inner fwd gear (from previous whacks in wrong direction).

Thanks all, and hopefully off to the dealer for parts inspection and purchasing. Line is busy.

If you need any more help try these guys they mostly work on old outboard but have a lot of info on newer ones
www.aomci.org/cgi-bin/yabb2/YaBB.pl?board=askamember
Mike aka pathfinderz1