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I'm trying to join my lower unit to the upper unit after replacing the water pump impeller. I can't get the lower unit up the last inch. Something is preventing it from going any farther. Is it the top of the drive shaft? I have a good work space and I'm able to rest my arms and try multiple attempts. By all rights, that lower unit ought to be cooperating unless the drive shaft is not meshing with the flywheel, maybe?
I was lucky to be able to hire a local outboard motor mechanic to fit the lower unit to the upper unit. He followed me to my house, did the fit, started the engine. Water came out of the tell-tale strong and he told me I did a good job of replacing the impeller! I will not replace the impeller by myself again, though, because an experienced mechanic is needed to rejoin the upper and lower unit. I did not damage anything during my attempts to do the job myself. I'm glad I saw what the water pump and housing looks like. I learned that the outboard does not have to be running in order to flush the engine - something I didn't know - and that some owners are lucky enough to have a hose at their docks so they can flush their engines after each use; something I can't do but will keep in mind for future reference.
I recommend that the impeller be replaced every couple of years - for peace of mind - but I believe, now, that it is wiser for a mechanic to do the replacement because of the challenge of rejoining the upper and lower units. Replacing the impeller was not hard and was rewarding work.
