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Starboard shaft is stuck and wont slide out!

Saltydog

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Year
2004
Boat Model
SX
Boat Length
23
Backstory:
Got this 2004sx230 a couple months ago. Starts and runs good and we took it out and everything was fun. (At 1st)
Had to replace the thermostate on one side (did both) did an oil change, had to replace the depth finder with hawkeye brand, reconnected the speedo hose, cleaned some connections for horn and lights to work. And we have been able to take it out 4-5 times.

Everything I've done so far has been helped along with reading from this group. So thanks.
However, I went to take off the jet pumps this morning to check the bearings like we did when we got it (heard some noises on last trip) AND the bearing on the starboard side was one trip from complete failure! So I decided I would pull it completely out and do the rebuild on both motors and try the "oil"(set up) instead of grease. But the impeller shaft will not slide out like the port side does? Yes all bolts are out, yes I gave it some luv taps, yes i eventually broke the rubber mallet, was able to take the rear/aft bearing out and the metal race and the housing slides for and aft on the shaft - BUT the shaft splines are stuck!
Anyone ever had this happen?
 

Scottintexas

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I remember a story about a jeep, tow winch and impeller shaft but that was a long time ago [flag]

I might suggest hooking up cargo winch strap to the impeller to something to put a constant tension on it and then try tapping the housing to see if it will break free, sometimes they're just tough, I had one slide in and out easily and one time I had to wonder what happened I had to pull so hard,


.
 

Saltydog

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Started with a little tappy tap tap...
Ended with busted knuckles and orange rubber flying!
That was my best mallet!
After I removed the aft bearing and all the crap inside there;
-The housing for the bearings/ spacer and the housing for the impeller move forward and aft about 3inches.
- with the nut put back on, I can slide the housing aft, and when the forward bearing hits the nut it comes to a complete stop, this creates alot of force aft on the shaft. But it will not budge.
- got under the boat and put a 2x4 against the shaft and gave it some hits. Will not budge.
- now I'm trying to imagine how that other guy attached his jeep winch to the shaft🤔 lol.
I dont have a winch but I'd strap a comealong to a tree 🤔
- I'd let JAWS knaw on it for awhile I thought it would help 😬
 

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Murf'n'surf

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Location
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Backstory:
Got this 2004sx230 a couple months ago. Starts and runs good and we took it out and everything was fun. (At 1st)
Had to replace the thermostate on one side (did both) did an oil change, had to replace the depth finder with hawkeye brand, reconnected the speedo hose, cleaned some connections for horn and lights to work. And we have been able to take it out 4-5 times.

Everything I've done so far has been helped along with reading from this group. So thanks.
However, I went to take off the jet pumps this morning to check the bearings like we did when we got it (heard some noises on last trip) AND the bearing on the starboard side was one trip from complete failure! So I decided I would pull it completely out and do the rebuild on both motors and try the "oil"(set up) instead of grease. But the impeller shaft will not slide out like the port side does? Yes all bolts are out, yes I gave it some luv taps, yes i eventually broke the rubber mallet, was able to take the rear/aft bearing out and the metal race and the housing slides for and aft on the shaft - BUT the shaft splines are stuck!
Anyone ever had this happen?
I had this exact problem. I had to use a 2x4 piece stuck through the intake grate and rested on the impeller inner hub then smacked wood with a 10lb hand sledge until it broke free.
 

Scottintexas

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Saltydog

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I had this exact problem. I had to use a 2x4 piece stuck through the intake grate and rested on the impeller inner hub then smacked wood with a 10lb hand sledge until it broke free.
I tried that too! How funny.
When you finally got it out did the splines look ok?
Right now I've got this image in my mind that some how they got all messed up and are mangled together like some Celtic knot or something.
 

Saltydog

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and here's a bearing replacement thread, we have had multiple members post their experience,




.
Great thread.
I actually already read it and that happens to be the reason I was out checking mine this morning. I had already set my mind to be ready to replace some bearings and go the oil route instead of grease.
But I never expected this shaft to make a permanent home in there.
It's a non High output to answer your previous question
 

Murf'n'surf

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They looked perfectly normal....no rust...nothing.
 

Saltydog

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They looked perfectly normal....no rust...nothing.
Looking back at your pics from 6yrs ago I see that the condition of the housing where the forward bearing sets looks pretty rough.
How did you get the old bearings out and the spacer? I'd really like to not buy the housing for that again if possible. But mine looks as rough as yours did.
 

Cobra Jet Steering LLC

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You may try rotating the pump backward or the P T O backward just in case there are grooves worn into the P T O and drive shaft splines and these are locking together not allowing the splines to come out
 

Murf'n'surf

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Looking back at your pics from 6yrs ago I see that the condition of the housing where the forward bearing sets looks pretty rough.
How did you get the old bearings out and the spacer? I'd really like to not buy the housing for that again if possible. But mine looks as rough as yours did.
I sent them off to RIVA Motorsports so they could have all the fun! I ended up buying a complete shaft and bearings on one because they couldn't separate the bearings from the shaft
 

AboveTheBest

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I used a 3’ piece of 1/2” black metal pipe and a mini-sledge to get my stuck shaft loose.
There is a small lip where the impeller goes over the shaft that you can get the pipe to catch on. It only took a few FIRM whacks with the mini-sledge and the shaft came loose.

However, my pump was absolutely trashed when I got it out, but that’s another story altogether (unrelated to the shaft removal).
 

Saltydog

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I sent them off to RIVA Motorsports so they could have all the fun! I ended up buying a complete shaft and bearings on one because they couldn't separate the bearings from the shaft
Did you have to replace the housing too?
My bearings and spacer are not stuck to the shaft though- they are stuck in the housing.
Mainly looked like the metal on the housing was rusted and chipping - in your pics.
 

Saltydog

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2004
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You may try rotating the pump backward or the P T O backward just in case there are grooves worn into the P T O and drive shaft splines and these are locking together not allowing the splines to come out
That's a good idea!
Now how to do that?
Starboard side prop rotates counter clockwise- and the nut on the end of the shaft screws in clockwise- I could use an impact wrench on it clockwise to see if it loosens the splines.
But what if I cant get the nut back off later?

Anyone know of a great reason not to try this?
 

Saltydog

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So - that didnt work, but I think I scared it a little.
The impeller isn't supposed to spin on the shaft freely is it?
It does now! I didn't do anything to it at all- just the impact wrench on the nut on and off a few times - let it vibrate the hell out of the shaft and the shaft didnt budge- but the impeller budged and now rotates freely and independent of the shaft?🤺
What item usually keeps the impeller in place? Is it just friction
 

Cobra Jet Steering LLC

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The impeller is left hand thread and it screws on to the shaft, Actually the hardest thing I have ever had to do on a Yamaha was remove the impeller , people have posts about driving a jeep on a breaker bar laying in their driveway to get that damn impeller loose from the driveshaft . I have no idea how your impeller is loose unless it is an old style aluminum one and it is just plain stripped. I have heard of the drive shafts actually fracturing, usually after the impeller was changed due to all the stress placed on it trying to loosen it. If you have not had any luck pulling the pump housing from the back of the boat and you have all the bolts removed I can tell you how I deal with that, I made a special end for a 5 pound slide hammer that allows me to catch the pump housing bolt flanges and while working a criss cross pattern I use the slide hammer to slowly loosen the pump housing until it comes free thus removing the drive shaft with it.
 

Saltydog

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Year
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The impeller is left hand thread and it screws on to the shaft, Actually the hardest thing I have ever had to do on a Yamaha was remove the impeller , people have posts about driving a jeep on a breaker bar laying in their driveway to get that damn impeller loose from the driveshaft . I have no idea how your impeller is loose unless it is an old style aluminum one and it is just plain stripped. I have heard of the drive shafts actually fracturing, usually after the impeller was changed due to all the stress placed on it trying to loosen it. If you have not had any luck pulling the pump housing from the back of the boat and you have all the bolts removed I can tell you how I deal with that, I made a special end for a 5 pound slide hammer that allows me to catch the pump housing bolt flanges and while working a criss cross pattern I use the slide hammer to slowly loosen the pump housing until it comes free thus removing the drive shaft with it.
I had no problem with the housing at all just the shaft.
Its stubborn
 

Cobra Jet Steering LLC

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It should slide out of the splines at the vibration dampener on the back of the engine the only other contact it makes is the intermediate bearing where it goes through the hull.
The impeller should not spin free I am still thinking the splines have worn and are interlocking with each other.
Try turning the P T O side of the vibration dampener back and forth to see if it unlocks.
 

Saltydog

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At last it's free!
Update:
- turns out it wasn't spinning freely, once I turned it all the way to the end of the threads it stopped spinning freely!
- I guess all the vibrations from whacking it and the impact wrench and everything else loosened it up
- also the starboard side engine has a plastic wear ring and the port side has metal, and neither prop shows wear? (16 yr old boat) gives me the impression someone has been in here been in here messing with stuff. Maybe they didnt torque it down?

-lastly - I got it out!
Pictures to follow
Took a ratcheting strap and attached one side to the trailer hitch and the other to the shaft.
Had to use a large spacer to keep all the threads from having any contact.
Tightened it as much as I physically could.
Split a 2x4 in half so I could use the smaller piece.
Smaller piece was able to go inside the intake grate better ( 90degrees perpendicular to shaft instead of 45 degrees)
Whacked it, cursed at it, threatened it, sweet talked it, gave up on it, then used both hands and the hammer to hit the strap end - where it was connected to the shaft.
3rd hit it finally came loose.

1 Can someone tell me brand name of stuff to use on threads for future?
2 Also would like to know what everyone likes for sealant between each of the jet pump sections?
3 how far in to set the new bearings when inget them?
Thanks everyone!
 

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