What purpose does the spring washer serve? Would a lockwasher suffice? What does the spacer do?

There's also a "newer" style rear mount that uses a knurled insert, and is somewhat different. Another possible issue is that if the old monts are shot, they will sag a long ways - to the point where new ones have to be pressed in before the engine will align properly. Sorry - can open, worms everywhere!

Has this engine been aligned with these nounts, etc... since the last time it was taken out? a little more info on the specdifics of what was done or not done since the last time it was aligned would be helpful in shedding light on the potential issues.

I don't really know. Engine was installed by PO. Stern drive not installed. I have an engine alingment tool right now, and I can only get it in about 1" or so, because the flare on the alingmnet tool hits the inside of the gimbal area. It goes through the gimbal bearing just fine, but there is a small flange inside of that, toward the engine. It hits there.

can you see/feel the back mount?

between the bellhousing and transom plate will be the fiber washer,,,, wont be able to see the sprging as its inside,,,, but if aligning the bearing doesnt help id go there next

Here is a link that shows the lock washer, its #8
http://www.mercruiserparts.com/Show_...ND+SHIFT+CABLE

How precise is the alignment? Will one or two turns of the front mounts in the wrong direction cause a bearing failure? I am pretty sure I'm close, I just don't know if it's "perfect".

If it's not close enough to get the alignment tool in, it's WAY off... you can smoke the coupler and or trash the bearing and seal in the drive upper... Sorry. I'm betting the po didn't put the rear mounts back together correctly... or that they're worn out and sagging.

is the alignment tool hitting the coupler high or low? Put grease on the end of it, push it in as far as you can, and then slide it out carefully and look at where the grease is disturbed...

When its perfect it will slide in easy and bottom out.

You will know when its perfect.

You will never get the drive on if its not.

No, the tool definitely goes in. About 1" or so.

That's just it. The alignment tool is hitting the top and bottom, and left and right. I think it is really close! Again, the tool I am borrowing is hitting the inside gimbal mount plate. The diameter of the last, largest section of the tool does not clear the inner gimbal mount area. It goes through the bearing, perfectly, but there is a lip on the inside gimbal area that is about 1mm smaller in diameter, and the largest area of the tool cannot pass that. It bottoms out on it.

cash, hope you get this resolved because I need my alignment tool back ASAP . Hoping you can return it before June 1st.