Brian,
Thanks for the info, and the link. What engines did you do your rebuilds on?
Thanks,
Dean

does it have to be drilled on the side of the pump to get the pin out first,,,not sure if a rebuilt kit is worth it or not

Yes, it does, and on the Merc pump I can't see where you can drill to remove the pin. In fact the pin on the Merc pump is swedged from the inside, I don't even see how you can get the pin out without screwing up the pump..... What a sh!tty design.

Dean, here is a photo on the one I did that I got from Holley. Look at my post #60 to get the part #'s

The pin slid out from the swege thru the hole I drilled. I then tap it and put in a set screw and JB weld on the outdide hole.

its not a bad job guys, if i recall i used a screwdriver a drumell and small punch,

Brian,
Is this where you ground out the stacking for the pin, (End of the screwdriver) BTW, sorry about the crappy pics, I will try to take some more later, Thx.

Dean after I drilled the hole, I pushed the pin out with a thin nettle nose pliers.

NO. go to www.428cobrajet.org/how-to-fuel-pump.html gives instructions and alot of pics, the kit i showed you comes with all the parts listed.

dean ,the pin looks like it has to come out from the side of the housing,,,to me it looks like you woulds have to grind some of the housing out of the way ,in order to get a straight shot at the pin,,is this what you see also???

Just another incredible Mercury PITA! I have not had a problem yet, but figure I better do something now rather than have it go bad in the middle of boating season.

Has anyone found a electric pump that will work to replace the crappy mechanical pump? Then run the old style raw water pump?