Lower unit pressure test failure: 95 maxum 2000sr 5.0 alpha one gen 2

[Hooks742010]

A small oil drip from the upper shift shaft lead to water in the reservoir. I’m working on replacing the transom shift shaft seals. In the meantime I pressure tested the upper and lower unit. It held pressure but when I fiddled with the lower shaft shaft it would loose air. So being the genius I am, I rebuilt the lower shift shaft and replaced the water pump. No the unit with not hold a pressure test. Slow contact leak at the new shift shaft seals (without “fiddling” with it) 🙄.

Any thoughts? Replacement shift shaft seal base parts are an updated version of the original. idk what I could have done wrong here but something up. I guess I’ll try to pressure test just the lower alone and see if I can narrow down what seal of the shift shaft base is having an issue. Bubbles come from center seal around the shaft but hard to tell exactly with upper unit installed.

[mmwjr]

With the new seal and base is there a need to replace the actual shaft? Does the old shaft have signs of wear at the seal interface?

[Hooks742010]

Originally Posted by mmwjr

With the new seal and base is there a need to replace the actual shaft? Does the old shaft have signs of wear at the seal interface?

No. The shaft looks great. It’s really a clean motor and outdrive considering it’s age. Craziest thing ever. There were three large orings that came with the new kit. Only two were used. My Dad use to always say manufactures might send you extra parts…but also I remember a lot of our stuff needed to be worked on 🤔 even after repairs lol.

I did not see a place for a third oring nor did the documentation or old parts suggest there needs to be one.
It shouldn’t have been this difficult. I must be missing something.

[mmwjr]

I see 1 x #36 and 2 x #37, or is it #6 which seals the lube passage between the two half’s of the drive?

[Hooks742010]

Something definitely is wrong. I used an extra seal inside of the new shift shaft base to seal on the shift shaft itself and the leak stopped. I’m still unsure if that seal was supposed to be there, I’m missing a part or the shaft is no longer good. The shaft looks great so I can’t see that being a thing but maybe with the update version of this base I should have ordered a shaft too idk. For now it’s working but I expect there to be more issues in this location. I’ll dig into the parts diagrams and manufactures info and post back results