dave wrote:
I pulled the lower unit on my 9.8 mercury outboard to check the water
pump.
I am trying to reinstall it, and everything appears to aligned
correct, but I can not get it to reassemble the last 1". Neither the
drive shaft nor the direction shaft have corrosion on the ends, and
neither is chipped or broken.

I had pulled it apart about a year ago, and reassembled it pretty
smoothly. I can not remember having to do anything special to
reassemble.

I can see where the direction shaft is engaging with the motor, from a
side view. If I wiggle the direction handle, I can see the shaft move
with it. So it appears to be aligning.

Anyone with any suggestions or tricks for alligning/assembling?

Before Attaching the gearcase housing to the driveshaft housing, make
certain that both the shift cam and the shift lever are in the forward
gear position. The shift shaft should be in the ccw position (viewed
from the top end of the shaft) and the shift lever should be pulled up.

Rob