I had a stuck gear case assembly from a Mercury KE4
Mark 7 or KE7 that needed to be broken down...could
not get cover to turn...I recalled a technique suggested by Bob Grubb...use punch and hammer to
tap around the outside of case over area where cover screwed into case...the percussion method...having
nothing to lose I tried it...the cover unstuck
and came off without amy trouble.
The gears and bearings were all chewed up so all I have to show for effort is experience and a new
(to me technique).
New to you and others who have never tried that method of removal. Thanks for the tip
One trial does not prove the method is a one size fits all solution. Several KE4 & Mark 7s need impellers checked...will post results when done.
Seems a less aggressive method than using a torch
to heat case until lube is hot enough to deep fry
and then using hammer and punch to drive cover off
...you do see a lot of covers that show marks of use
of hammer and punch to drive cover off and then on
again...kind of hard on covers.
I have the correct Mercury Service Tool but it will
not start a stuck cover.
I use the correct tool with a short hex bolt in it with an electric impact wrench. I heat the area around the cover with a mapp gas torch for about 10 seconds then use the impact wrench. The covers come right off.
If corrosion looks really bad: I tap the outside of the housing very lightly all the way around where the cover threads are. I think this helps breaks loose salty crud.