Underdog lower the drive down on the motor that has you worried and have someone with some weight stand on it and bounce while you observe the transom ,epecially down low.Sounds like you might have a rotted transom issue.

GOODT…. I have a drive alignment problem. I put new transoms assy on my boat. I’m trying to push the alignment tool in but it won’t go. Moving motor up and down the full range of the mounts. I finally crawl down on was able to feel where the tool was hitting…the tool misses the coupler by the height of the bushings on the back mounts. The new transoms do not have the spring washer, but it is almost the exact length of the washers. Can I take them out and let the bell housing just rest on the fiber washers?

The first part of the alignment is aligning the bearing. The bearing can pivot in the race. Hard to describe unless you have worked with these types of bearings before, similar to what is used in a machinery shaft pillow block. You can pivot the bearing to "aim" it towards the coupler by tapping or pulling up/down on the alignment bar. You aim the bearing/shaft so that it will hit in the center of the coupler, then adjust the angle of the engine so that it will slide all of the way into the coupler.

Ain't that the truth! I was helping aligning a motor after a new transom assembly was installed. We scratched our heads for hours trying to fugure out how in the hell the motor could be off 1"! Finallly pulled the motor back out, removed the inner plate, and found nothing wrong. Reinstalled the plate, then for some unknown reason, we put the alignment tool in the gimble bearing for chits and grins, and a light bulb lit up! You know you can swing that tool around in a 12" arc?
Dropped motor back in. Perfect.

Bet we ain't the 1st to realize that a simple 5 second oversight can lead to hours of fustration.

I forgot to mention about the mounts. Newer rear engine mounts don't use the spring washer, the mount is longer on the bottom and is "serrated". In a mount kit is usually an extra stainless washer that can be used underneath the mount, but only if you have a height problem. Mercruiser decided that the mount should be slightly lower, the washer is included for existing installs where the alignment was originally done with the spring washer setup to keep the original alignment. New installs or if you are able to correct the alignment you shouldn't use the washer. If you don't have the new mounts, I think you still use the spring washer.

1) New mounts with taller serrated bottom, no spring washer, ss washer optional
2) Old mounts, smooth bottom, spring washer still used.

[Ain't that the truth!]

Bet we ain't the 1st to realize that a simple 5 second oversight can lead to hours of fustration.[/QUOTE]

Yep that did the trick. I should have know that bearing would move like a spherical bearing.
Falcon thanks for the heads up.
Now I just need to figure out how to reverse the cables on the shifter so the drives counter rotate , going from B3 to B1

if they are k kieffer shifters they are very easy if they are gaffrigs a little harder either way just reverse the side of the shifter they are hooked to

Thanks to everyone for the gimbal bearing alignment info.

I was experiencing the exact same engine alignment delima as many others and so I tried smacking the alignment tool from the bottom in an upward strike using a short piece of 2 x 4 against the tool and a 3 lb handheld sledge hammer. One slight upward impact on the 2x4 realigned the gimbal bearing so the tool slides in and out easily with two fingers. I had the alignment tool inserted only as far as it would go without entering the actual splines when I used the sledge to pivot the gimbal bearing. After the single impact the tool slid right into the splines.

The front mounts are about all the way down but I'm gonna take the advice given here and trust the alignment tool and lock everything in and reinstall the sterndrive.

Many thanks!! Reading this thread saved me countless hours of additional effort.

Who are these guys ? a sledge to align? Leaving the tool in and raising the engine? good way to bend a good tool. Did they just use the shaft of the tool? OK for experienced. bell housing not parallel to tool unless picked up ? Pie pan used to take care of that

In order to align an engine, can you bolt the engine down to the hull mounts? or is it a good idea to use the alignment tool, set it if needed and then bolt engine to stringer mounts?