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2006 4 stroke 3.5hp Mercury. shift lever will not move. pulled power head and disconnected shift linkage. We cannot get the lever to turn or come out of housing. tried various lubricants, mild heat, tapping, turning with vice grips on inside, etc...nothing working. Suggestions?
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Conclusion
He drove the rod in a ways, cut off the inside ear and then worked it out. An engineer on another thread suggested using a heat gun to expand the aluminum housing hole, making it easier to remove the steel rod. would have been a lot easier.
There was corrosion around the rod at the inside o-ring. Yes, they put a stainless rod through alum. housing WITHOUT a corrosion barrier. When we put the new one in, we will coat it with TEF Gell and try to figure out if there is anything else we can do to keep it clean and lubed. Looks like 10 years is too long in salt water for this construction. For those of you with younger motors, you might want to do some preventative maint.
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