When I bought my new shaft from Catalina Yachts I also replaced the coupler and had the new one "married" to the new shaft. You should be able to clean the old one well and install it to the new shaft if its the same diameter. Just line up the key with the slot in the coupler. If its stuck to the old shaft still try heating up just the coupling and use a puller to remove it from the old shaft. Be sure to run wire back through the set screws to keep them from backing out while you are under power.

Below is a picture of the new shaft and coupling and the second picture is of the two set screws that need to be secured with wire.

[QUOTE=2sailaway;17081]When I bought my new shaft from Catalina Yachts I also replaced the coupler and had the new one "married" to the new shaft. [/QUOTE]

Larry, I've always wondered how you get both the shaft and the coupler INTO the boat - do they get "married" after the shaft is in? How does that work? Can you tell I haven't had to do this?

Stu,
You have to assemble after you get the shaft into the shaft tube and strut, Then you can assemble the shaft and coupler than the coupler to the transmission.
With luck and the prop off you can get the shaft past the rudder, so do not assemble the prop thinking you can just slide it in.

Hey Bill,

I just did this myself a few weeks ago, and can tell you it's very tight in that engine compartment for getting everything put together again.

I was replacing my damper plate at the same time, so had the transmission off the engine, which gave me more room to work with (I don't think there's any way I could have gotten the shaft into the boat otherwise, without dropping the rudder). I was also installing a PSS and new cutlass bearing (since I had everything out anyway), and that made for even more of a tight fit. Here was my process:

1. With transmission removed, slide new shaft (without coupling) into boat from outside (should just be able to sneak it into the shaft log, and far enough into the boat to clear the strut, then bring the shaft back down through the strut/cutlass bearing. There was no way I was going to be able to slide it up through both the strut and shaft log in one shot without pulling the rudder, just didn't have the angle).
2. Install PSS (which had to go on before the coupling), then attach coupling (I used a split coupling, which made this a lot easier). Getting the coupling on is no mean feat, since there's very little room to swing a mallet. Having the transmission out was the only way that was going to happen (unless you attach the coupling to the transmission, and hammer the shaft into the coupling from outside. That'll be hard, since you'll need to make sure to get the shaft the correct depth into the coupling to line up with the pre-drilled setscrew divot).
3. Once the coupling was on the shaft, I re-installed the transmission (again, damn tight squeeze, barely enough room to get that sucker back on with the PSS and coupling in place).
4. Tighten everything up, adjust PSS, install new cutlass bearing, attach propeller.

Have fun, I know I had a highly-enjoyable day with this particular project....

Well, after reading through this I feel silly. I was able to get the shaft into the boat easy, all I had to do was remove the motor.:( I was doing this as part of a bigger project so I decided to try this the other way, past the rudder. This worked (just barley) also with a little "push & wiggle" move. Its a tight fit but can be done just be careful not to bend the shaft.

[QUOTE=stu jackson c34;17083]Larry, I've always wondered how you get both the shaft and the coupler INTO the boat - do they get "married" after the shaft is in? How does that work? Can you tell I haven't had to do this?[/QUOTE]

Hi Stu,

According to the catalina direct website they custom fit (drill) the hole to fit the new shaft, it wasn't to much so I paid the extra for this process. Its called "facing" not married, that was my term for lack of better words. You can find the info on their website below.

[URL="http://www.catalinadirect.com/index.cfm?fuseaction=feature.display&featu..."]http://www.catalinadirect.com/index.cfm?fuseaction=feature.display&featu...