Frozen Gear Lever (3/3): replacement in a Mercury 2.5hp outboard engine

This is the 3rd in a series of 3 movies showing how I changed the gear (shift) lever in my outboard. The gear lever had become frozen due to salt corrosion over the winter. It would not go into forward gear, completely stuck.
This shows me putting the whole Powerhead back together and testing the engine.
Links to each of the series of 3 movies.
Part 1/3 • Frozen Gear Lever (1/3...
Part 2/3 • Frozen Gear Lever (2/3...
Part 3/3 • Frozen Gear Lever (3/3...
I found this CZcamsr's movies useful
Channel: / @oldguydiy
Movie: • OldGuyDIY 4HP 5HP Merc...

[@domingo630]

Thanks for sharing. I will be tackling this exact project this winter with my 3.5. Very helpful!

[@MikeMartinCardiovet]

Good luck

[@rvdogfl]

Great job of making the series of videos. Thank you for the info

[@bobbourne3874]

I had the exact same problem and also had to angle grind the shaft and punch it out, it's a bad design l think,why didn't they incorporate a grease nipple in the casing! Thanks for the video, very well explained 👍

[@artichokeheartful]

When you re inserted the gear linkage . Did you use a new linkage as the other one was Bent from hammering with screwdriver and hammer ?

[@MikeMartinCardiovet]

Yes I bought a kit from eBay.
www.ebay.co.uk/itm/273134448045

[@zack9633]

I searched CZcams for quite sometime until I found your three videos. I knew I would have to do the same but was looking for an easier way to deal with this problem. the exact same problem on a Johnson 6HP 4 Stroke. now that you have done it, are there any tips you can share? or any idea if it can be done in an easier way?

[@MikeMartinCardiovet]

I would hammer less, as I think that caused a small bend in the lever spindle. But it that does not work, I'd do the same.

[@zack9633]

@@MikeMartinCardiovet I am thinking of drilling the hole where the spindle sits, and inject some sort of vinegar or salt dissolving liquid. it is the two o rings on the spindle the prevent anything except salty water from penetrating into that cavity.

[@MikeMartinCardiovet]

@@zack9633 Sounds like an interesting idea. Good luck. Let us know how it goes.

[@joshuayunker1475]

Where did u find the part for it? I’m in this same boat right now

[@bobbourne3874]

eBay sell them

[@MikeMartinCardiovet]

www.ebay.co.uk/itm/273134448045?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=sTfCO1oEQd6&sssrc=2349624&ssuid=iozd1SyZQge&var=&widget_ver=artemis&media=COPY