Just curious, what brand of props?

Bravo 1 4 blade SS, 30P.

I've had hubs that were very tight before. I agree with mobilemercman about it's not caused by torque value. You could try a LITTLE heat with the puller. If all else fails, and I'm sure you would rather avoid this, after removing the retainer the entire propshaft and carrier assembly may be removed. Before I went that far I would try a bearing spliter behind the hub. I believe their is room for it. The OTC brand we use has two tapped holes that can go through a VERY heavy bar we have that pushes on the end of the shaft. Like Vegas said put the nut back on but as far as you can and still have room for movement. If it's barely on you may damage the first couple of threads. As Knot4Me said greasing the splines is critical.

I use Castrol Mo-Lub-alloy on the shafts, works great. It's a water proof black grease.

Success!

I successfully removed the hub tonight after buying the correct tool at Sears. It is a two prong (I wanted 3 but they didn't have any) gear puller with 6.5 inch reach. Came off with no problems and there wasn't any damage to the hub or splines at all. It was just too tight to remove by hand. I don't think the puller was working very hard at all, but it was still to tight for removal by hand. I greased it up good with merc salt water grease and put it back after completing my oil change.

By the way, it was really tight going back on even with the grease. I couldn't get it to completely seat (last 1/2 inch or so) until I torqued the prop nut. I suspect I may need the puller in the future. I don't see this as a problem now that I know how to deal with it and I have the right tool.

Thanks again for all the suggestions and help. It's nice not to feel totally alone with these issues when they happen and also to have a place to vent just a bit when things aren't going great.

John

Good!
I´ve got three of those hubs that slide on real easy, and a fourth one that has had the most use is real tight. Strange, huh?
Get out on the water and enjoy..........

Excellent! You might try a different hub to see if it is the hub or the prop shaft that is the problem with the hub not fitting easily on the prop shaft. It should slide on and off easily. Now, go enjoy that new boat!!!

Why don't you try that hub on the other drive and see what happens.

Good idea. I'll give swapping the hubs a try. Sure doesn't look bent to me, just snug, but we'll see...

Also, the boat runs flawlessly with no shaking or shimmering as far as I can tell.

I wish I had that problem (brand new 2008 32 Sunsation)