Will, there are pictures of a PSS installation....
Will,There are pictures of a 310 PSS install on my web site. The pictures are located here: http://www.pbase.com/mainecruising/image/72621934and here: http://www.pbase.com/mainecruising/image/72621935Just call PSS they know the diameter of the PSS to use on a Catalina. If my memory serves me correctly the stern tube is an 1 5/8 OD but PSS only makes an 1 3/4 and it fits well. Here's how to install just the PSS.. The process is fairly easy and the pics above may help. Day One:1) Loosen the packing gland nut.2) Loosen & remove the four nuts between the transmission and coupling.3) Push the shaft towards the stern separating it from the transmission.4) Spray the shaft and coupling with PB Blaster or Thrust. Do not use WD40 or Liquid Wrench these are NOT true penetrating oils. PB Blaster or a product called Thrust are incredible products!!Spray both the prop end of the coupling and the transmission end by sliding the shaft towards the stern tube. Then align the shaft upright and remove the seizing wire and two bolts that lock the coupling to the shaft. Next fill the two bolt holes with PB Blaster, wait a few minutes for it to absorb into the holes and repeat a few times. By hitting both ends of the coupling, and the center where the holes are, with PB Blaster, you will get better Penetration than just spraying the prop end of the coupling.Day Two:5) Insert a deep drive socket that is slightly smaller than the shaft size between the center of the shaft and center of the transmission hub.6) Insert four long FINE threaded bolts, preferably without shoulders (the part on longer bolts with no threads). Ignore the bolts in picture below as I did not need fine thread. This pic is for illustration purposes only. My boat was only a year old and the coupling was not that tough to get off compared to my last boat a 1986 where I did have to used FINE thread. Be sure to use washers between the coupling and trans hub and begin tightening evenly. Be sure to put never seize on the bolt threads to prevent galling it will also make it easier to turn the wrench. Coarse threads will not work as easilly on an old coupling so be sure to use fine threaded bolts.7) Afer some initial tightening, and with the bolt pressure still on the shaft and coupling, you may need to go outside the boat and strike the prop shaft towards the bow, yes the bow, with a dead blow mallet to break it free. Use a scrap piece of maple between the malet and the shaft to prevent potential damage to the end of the shaft from the dead blow. Then re-enter the boat and continue tightening until the coupling is off the shaft.8) Optional: Bring the coupling home and clean and paint it with a rust proof paint.If you have trouble getting the shaft and coupling apart you can heat the CENTER of the coupling very slightly with a blow torch (make sure you have an extinguisher on hand just in case) heating it in the CENTER will draw the PB Blaster into the coupling due to capillary heat draw. Use this as a last resort only.P.S. When re-installing the shaft and coupling apply liberal amounts of Tef-Gel mixed with Never Seize. Coat the shaft and the inside of the coupling and you'll be able to get it apart in the future! If the coupling does not want to come off the shaft with the above method, without serious overtightening, have a piece of 3/8 steel cut with the same hole pattern as the coupling. Use this pice of steel, with the socket in between, instead of the transmission output hub, to break the coupling free. The transmission output hub CAN be broken if you over tighten! This is why it is safer to break the coupling free by hitting it towards the bow and not the stern..Do not forget to sand the shaft and remove any burrs before sliding the rotor face onto it. Inside the stainless steel rotor face are two o-rings. If you slide these o-rings over a burr you may cut them and have a leak! Use dish soap to slide the rotor onto the shaft after de-burring with wet sand paper or a small file if necessary. The shaft should be as smooth as glass when you rub your fingers on it. I put one of my wifes scrap nylons on my hand and rubbed the shaft with the nylon covering my fingers. If the nylons catch on any burrs more sanding is required. Be very careful to ONLY sand the burrs and not to reduce the diameter of the shaft or a wobbly coupling could occur. The burrs are usually along the "key way slot" & the "set screw holes" but could be other places too...