The ring gear on my 502 flywheel is loosing some of its teeth. Can I assume that a ring gear for the same size GM flywheel - (assuming it’s a 168 tooth gear ) will work just fine or do I need to pay the boat tax? Pulling the motor in and out sucks.

Any GM 168 tooth ring gear will work. Summit has them for under $20.00.

GF?

GF?

GF = Got Freedom.
his handle

Ayuh,...... You can just knock it off with a punch, flip it over, 'n reinstall the same gear,....

Going back on, heat in yer oven, 'n it'll fall into place,.....

Got a new one on the way, let the party begin. Anyone have any tips on setting up the alignment?

engine or starter?

alignment of the engine to the outdrive.

You will need an eng alignment tool to align eng to outdrive via the gimble bearing. They are fairly cheap online. Highly recommend picking up a tube of Merc spline grease for the outdrive input shaft (and alignment tool). 1 tube will last you basically forever.

Before re-installing eng and before re-installing bell housing, mount the starter and engage solenoid to verify it's aligned properly so new flywheel teeth don't get chipped. With bell housing removed, you will have a front row seat to the starter/flywheel engagement and can easily take measurements/make adjustments.

Verify the starter bolt knurling is the correct size, otherwise the starter can move around and mess-up the alignment with the flywheel teeth. If everything is orig, you should be OK. However, I've experience mini-starters that needed "stepped knurling" on the starter bolts.

If you find 2 large fiber washers and 2 really short springs laying in the bilge after removing the eng, hang on to them. They will be needed going back in.