Outdrive swivel pin replacement

Confronted with this problem on a salt-water Alpha, I used a sturdy ball joint puller to push the lower pin out, hoping to shear the remains of the cotter key on the way out, as mentioned above. Although this has worked for all-steel vehicle suspensions, it did not work here -- the pin drug through the fiber lower bushing and tore out a little bit of the aluminum casting. Both of these could have been dealt with (replace bush, live with small aluminum nibble) but I broke the lower yoke in the end, and replaced the casting with a much nicer one shipped over from Minnesota (land of fresh water lakes) Although costly, this actually solved a plethora of corroded-related damage for me. In hindsight, I would recommend the tip to drill access holes in the housing to drive the pin out first, then check not to use excessive force driving the pin out.

On a related note, I made short work of the super-corroded top pivot by using a torch to heat the rusty cross-bolt and top nut and the exposed end of the pivot pin (on the bench, lots of access). Fortunately, the last did not appear to ruin the ($400 OEM) pivot pin for reuse. Various pentrants and "easy-out"-type drivers barely work for me but heating to dull red works every time.
 
As an addition to the problem of the cotter key in the lower pivot pin. Simply re-drill a new hole to hold the cotter key so there's a clear path in driving the cotter key out.

Originally, the lower swivel pins were steel. Then they went to aluminum. I'm not sure if merc ever put in a new hole to make removal of the cotter pin easier but I have sheared off the cotter pin even with the new aluminum swivel pin. Just be careful to line up the drift/punch carefully before you smack it with the sledge hammer. Don't wanna crack the gimbal ring or outer transom assembly.
 
steering arm leakage is due to the grease fitting that was removed by Mercruiser. It can be added at any time
without much trouble. Once you locate the center of the brass bearing,drill thru the housing slowly until you see brass chips ,and then stop.Change out the 1/16th bit and use the correct bit to drill the hole to tap for the grease fitting thread. tap and install grease fitting .
I have a broken GEN II housing I have to replace and will use that for photo installation of the grease fitting and dimentions. And the new housing will have the grease fitting installed too.
 
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