I've got a 1993 Evinrude 20hp 2 stroke outboard (model # E20CRLETS) that I just replaced the water pump kit on. I changed it because there was no water coming out of tell tale when I had it running on the muffs. All last year water flowed freely from it while I was using the muffs. I'd done all the checks to make sure there were no obstruction from the water tube in the lower unit through to the end of the tell tale tubing before replacing the pump.

I changed the kit with it in neutral (it was an OEM kit) using the manufacturer's instructions that were included with the kit. I put the lower unit back on, then ran it on the muffs and in a plastic tub - still no water from the tell tale. I took the lower unit off again, re-checked everything (gaskets, key in the driveshaft, impeller put in properly, bolts, etc). I went to put the lower unit back on to test it again but it won't quite go all the way in - it's slightly more than 1/4" out. When I put it back together the first time, it went in fully with no gap at all, though I had to turn the flywheel a bit to seat it properly. I've tried several times now while moving the flywheel and still always end up just that 1/4" out.

​I've read that the splines at the top of the drive shaft may not be quite in line with the shifter gearing? The water tube isn't a problem - I removed it entirely to eliminate it as a potential cause of the gap. I can easily re-install it once the gap is no longer an issue.

Would love some help with this