This was the trickiest repair so far. I dropped the lower unit to check everything out and replace the impeller. The lower unit was stuck so I needed to use a couple putty knifes and wood wedges to get it to drop. The two locator pins were corroded into the housing. I was afraid the shaft was stuck. I had read horror stories about cutting the shaft to separate the two.
Everything else came apart ok but the impeller's woodruff key was pretty corroded and I was afraid it could spin inside the impeller. I ordered the key from boats.net and took it all apart again. The new (and old) are steel. I tried round punches, vise grips, and dikes to get it out. There wasn't much to work with because it was corroded and already rounded over. I took out the dremel with a fine cutoff disc. Split the key in two and it came out easily. The new key was pretty tight. Had to smack it in with a brass hammer.
