So I completed the rebuild of my intermediate housings this week, and managed to do it without the shaft holder tool or the coupler removal tool. I did use a 12 ton hydraulic shop press from Harbor Freight ($140) and I needed a pair of large retaining clip pliers ($90 @ Napa). The small 6 ton press won’t work as it doesn’t have a large enough opening.
I made a jig to support the steel arbors that came with the press to be able to press the shaft out of the housing with the coupler attached. I used a block of hard wood between the press ram and the female end of the shaft so as not to Worked like a charm.
Once I got the shaft out, you have to remove the seals from both sides to expose the retainer clips holding the bearing in place. Make sure you pay attention to the sequence and direction the seals face for reassembly. I had to use vice grips and a screwdriver to get the seals out. You’ll need to put some muscle into it. Once they’re out, you’ll use the retaining clip pliers to get those rings out of both sides. These are large clips so a small set of pliers won’t work.
Once you have everything apart, you can start reassembly. Clean out all the old grease first. When you repack the bearings and seals make sure you use marine grease as it typically contains lithium and lithium and non-lithium grease cannot be mixed. So whatever you pack it with, make sure you use the same for ongoing maintenance.
I started by putting one of the retaining clips in first. Followed by the bearing. Pack with grease. This allowed my to press the bearing into place directly against the clip. When you use the hydraulic press, don’t go crazy with it. Press the bearing slowly and once you feel the resistance against the clip stop. Check it and keep pressing if needed. I used a spare washer I had and a short piece of pvc to press the bearing into place. Once the Bearing is in place, make sure you have enough grease to fill the space, Insert the retaining clip on the other side of the bearing. Next Pack the seals full of grease and press into place. I actually did this by hand using the pvc pipe and a rubber mallet.
Once all the seals are in place. You can press the shaft and coupler back into the housing. I placed the housing face down on the metal arbor so the shaft could pass through the opening as I pressed it in. I had the ram on the press directly in the center of the coupling. Slowly press the shaft into the housing until there is 9.5-10.5mm of the female end of the shaft protruding last the edge of the housing. If you press it too far, you’ll have to reuse the jig and arbors to push the shaft back out and adjust again.
Good luck and happy to help anyone out with questions.