Packing gland clearance issues.
Dear Dferr, I too had a similar experience with the coupling and packing cup interefering, necessitating hauling and removal of the shaft in order to change the packing. Well I only did this once right after getting the boat 12 years ago. Since then I've cut the fiberglass shaft log back 1 1/2" (I'm holding it in my hand as I type this), enough for me to now access the packing in the bronze cup before it hits the back of the coupling. As for getting the coupling off, consider removing the bolts by whatever means including knocking them off with a cold chizle and hammer and loosening any set screws into the shaft side. Then with a new set of bolts at the ready, insert a large nut between the end of the prop shaft and the back of the transmission output shaft and begin to tighten the new nuts and bolts, forcing the coupling halves apart and off the prop shaft. With a bit of cleaning and painting, you might even be ble to reuse the old coupling. As I recall, when I bought all new bolts for my coupling they ended up being case hardened. I'm not too much of the waterless seals as the technology surrounding conventional packing has advanced to much in the last 20 years as to make the new packing with Teflon impregnation, coupled with Teflon paste added, so efficitent that it not only runs cool but doesn't even drip a single drop at all. Then if and when a drip does appear, it's a simple matter to tighten the cup several degrees to staunch it and you're good for years more drip-free use. You already own your old packing so if it ain't broke, why fix it? Aside from the four bolts and some new Teflon packing, I can't see much more cost other than your time to do the repair. Hint: If you can't cut the shaft log back far enough, look to see if you can shorten the black hose joining the log to the bronze barbed gland nut assembly to gain a little more room. Also consider using ABA or AWAB Swedish hose clamps available at West Marine to replace any old Ideal clamps that might be there now. The new ones have a different pitch and are less prone to vibrating loose and causing a potential leak there over time. Go for it, Glyn Judson, E31 hull #55, Marina del Rey, CA