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Hey Guys,
So a new Whaler season is upon me and I just bought a 1980 Merc Short Shaft 40 for my 1969 Whaler. I want to punt a new prop on the motor, But it won't budge off the shaft. When I pulled the king nut off the end, I saw the grease had turned to dust. I am fearing it is fused. Any Idea's on how to get this prop off?
Thanks,
Sean

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I would try penatrating fluid and tapping on it for several days and then a gear or prop puller. You may have to get someone that knows what they are doing to cut it off.

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There is also applying heat, in combination to multiple spraying of penetrant. If you are not experienced, have someone do it who is.

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Try a Rubber mallet too.

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Or a big hammer.

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Penetrating oil and after a few hours of soaking....use a flywheel puller. Of course, you should try the various types of hammers mentioned too.

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Use 'PB Blaster' penetrating spray. God made it.

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I like "Aero-Kroil" (will seep into 1000th of an inch), heat, pressure, and penetrating oil. You might need that "Fly wheel" puller.

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I would discourage the use of hammers. If your prop has a rubber bushing, heat will destroy it. A bearing puller is gentle and effective. If it rips the prop off the hub you can reset the puller to pull the remaining sleeve off the propshaft. If you really like the prop you just removed, you can have the bushing replaced for less that $100 at a prop shop.

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Just got the news from my mechanic. He has had it for over a week and he can't seem to get it off. Any ideas for this guy?

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You'll probably have to get a qualified mechanic and I repeat qualified to cut it off

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That's what kills me. He is a Cirt. Merc. machanic.

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I think it can be removed with a gear puller. Get the motor back, and rent a heavy duty gear puller. Put as much pressure as you can on the thing and leave it for a while. You can hit the puller with a hammer, the try to tighten some more, if it moves at all, then keep up the process, if not leave it under pressure overnight, try again in morning, tapping and tightening. I have removed them seized like yours, be patient, keep trying, it will come off. Don't bother with oils, they won't get through the corrosion. Heat will help, but not to much, as you can cook the prop shaft seals.

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If it's to that piont, I would take the lower unit off and put it on a hyd. preess.

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Our local Johnson QUALIFIED MECHANIC went to a one week Johnson School. Do you think he's qualified! He surely does not know how to use a torch or a tool other than his starter Johnson tool kit.