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  1. #1
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    what does it cost to rebuild a 2.5 sport master gear case?

    I have a old salt water 2.5 sportmaster that i just put a waterpump in and noticed how bad the drive shaft was corroded and rusted. Now it is leaking water into it. I have been told my best bet is to buy a 3 liter 25 inch shaft and have it cut down to 20 inch and resplined. But what about prop shaft is it going to be rusty as drive shaft when disassembled? Also this unit is real hard to get shift shaft adjusted whare you have forward and reverse, when you get forward adjusted it some times will not fully engage reverse and vise versa. So now i probably need gears to? I have seen two nice 2.5 sportmasters in the lower units for sale today for 2,700 dollars each, seem to be in good shape but with my luck something would be wrong with them by the time i got it installed on my motor! So what is the average price of getting a fully rebuilt sportmaster go for? Or is it cheaper and wiser to buy a used one for around 3,000 dollars and take your chances you will get a good one, although i dont have that kind of luck with used stuff. I am hopeing a rebuild will be considerably less but i just dont know. And who around Florida is the place to go? I know there are lots of variables, i am just looking for general prices some of you have paid in the past. Thanks
    Last edited by robert jordan; 10-29-2020 at 01:47 PM.

  2. #2
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    Impossible to even estimate rebuild cost. Far too many variables.

    There is no reason to suspect the propshaft is bad provided the unit has had good oil maintenance.

    Best to open up the unit and get an assessment, then you can make better decisions. There are a couple methods for repairing the driveshaft which may, or may not be suitable for your application.

    Being real salty complicates it a bit. Might have to wreck the carrier nut or even the carrier to get them out.

    I'd risk a couple hundred bucks to find out where I stand with the unit you have.



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  4. #3
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    Good luck finding someone who knows how and wants to do it. Let anyone to build one up for salty water.

    SEI needs to start building these. For what they cost to maintain I'd take a couple disposables from them.

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  6. #4
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    Dave Dreifort in Vero Beach, most professional and best customer service no question.. Damn near need to harass half the "Hi Pro" shops to answer the phone
    Last edited by aggiestckl; 10-29-2020 at 04:51 PM.

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  8. #5
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    Quote Originally Posted by aggiestckl View Post
    Dave Dreifort in Vero Beach, most professional and best customer service no question.. Damn near need to blow half the "Hi Pro" shops to answer the phone
    ...please translate that second sentence for us. thank-you.

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  10. #6
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    Also Craig C, depending on who you are closer to as a Florida guy.

  11. #7
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    Florida salt water is the Darth Vader of salt water from what I have heard.

  12. #8
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    Quote Originally Posted by Greg G View Post
    Florida salt water is the Darth Vader of salt water from what I have heard.
    I like that analogy. Not having dealt with other salt water I can only assume your correct.

  13. #9
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    I'm at the point of gathering knowledge and the special tools required to start rebuilding them myself.

    If anyone has a full set of the merc lower tools required, PM me.

  14. #10
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    Quote Originally Posted by FUJIMO View Post
    ...please translate that second sentence for us. thank-you.
    Real people that actually KNOW HP stuff are really rare and sought after. And have way too much business to answer phones.

  15. #11
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    What is going to be found inside you probably won't like. When I get these things from salt water it's luck if the housing is even usable. Usually the shift shaft survives

  16. #12
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    Hey Capt. , I know your probably right, Man i hate salt water but living in Florida its hard to avoid.

  17. #13
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    Only one Merc tool needed .... A big Hammer.....Just kidding. The Shift problem ,,,, might be the cable in the wrong position in the box. I would look for a seal saver/ sleeve.

  18. #14
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    Buy a 30" 3 liter shaft, cheaper than the 25" if you can believe that Chris Carson down the Keys and very familure with salt lol

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  20. #15
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    Quote Originally Posted by Whaaaaat View Post
    I'm at the point of gathering knowledge and the special tools required to start rebuilding them myself.

    If anyone has a full set of the merc lower tools required, PM me.
    I bought the tools needed and a manual from a Chaz friendly dealer. Anyone who can comprehend what they read ... should be able to strip one down , assess what needs to be replaced , buy the parts , and hang it back together ...

    Ohh vnemous ... buy the single bearing 3.0L shaft , push the collar off and throw it away ... now ya gotz a Hi-Perf .. two bearing shaft .. That Kevin you work with sure knows his stuff ..

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