I’m trying to disassemble the main furler gearbox/manual furler. 

I managed to take it of the mast and open the top cover, but I’m stuck getting the shaft out, it seems like the manual furling assembly is preventing me from pulling it out.

If anyone has any tips that would be much appreciated 

Cheers Alex.

Maramu 1986 

   In currently have both the main and the mizzen furler manual boxes on my Maramu apart.   I have obtained the needed seals and O-rings to reassemble these boxes but am struggling to find Alumaprep and Alodine  here in Turkey to help prepare the aluminum cases for primer and paint.   What aspect of the disassembly are you concerned about?   

James Alton

SV Sueno

Maramu #220

Marmaris, Turkey

   I am attaching some photos of my main manual furler gearbox.  On my boat, the  main manual gearbox cannot be removed without raising the furling extrusion enough to clear the cup that the extrusion is inserted into at the bottom.  To raise the furling extrusion and make room for removal, you need to loosen or remove the four bolts on the top of the mast to release the large anodized aluminum plate on the top of the mast.  The anodized aluminum part I will be referring to is shown is being held by my wife in an attached photo. Note the large aluminum tube that extends down into the mast sail cavity.  The main furler extrusion rides inside this large aluminum tube and is captured by a phenolic ring screwed to the aluminum tube so that the extrusion cannot be withdrawn downwards more than a few inches.  My masts are down removal of the anodized part was an easy job but I think that it should be possible to remove the main manual gearbox with the mast still up and I will be trying this when the time comes to service it again.  One would need to have a safe haylard to go up on other than the genoa and main haylard since those two haylards are supported by the anodized aluminum part that needs to be raised.  I would first remove the four retaining bolts for the anodized aluminum part one by one, replacing them with a longer bolt, perhaps  around 3" long.  Once this was done the anodized aluminum part could be raised and blocked with wooden blocks to a height that would allow removal of the manual furler gearbox.  Since the furler extrusion is retained in the anodized aluminum part, you will need some help lifting the fairly heavy extrusion while you raise the anodized part and place blocking under it.  So once the main furling extrusion has been raised clear of the main manual gearbox, all you need to do is to lower the motor and gearbox by loosening the bolts on on the mast to slide it down and to then remove the two bolts holding the manual gearbox and it can then be slide out of the mast.  Top open the box you need to remove the 4 hex cap stainless screws that hold the case together  (see photo).  I would suggest treating these screws like a stuck bow thruster if they don't come out easily.  Mine had been in place for 34 years and I was able to remove all of the bolts without any breakages.   I soaked the screws with pentrating oil, tapped, heated, tried to gently remove them back and forth and repeated until all were removed  (btw, the mizzen manual gearbox is the same exact box on my boat except for the stem shaft passing through the mast being a different length on the two boxes)   Once the screws are out, my gearbox opened easily.  Below is a list of the seals that were in the gearbox:  The seals were the same for the mizzen manual gearbox.

   Glad to hear that you were able to remove the manual gearbox.  Best of luck with the servicing.  I found that the bolts were mostly stuck by corrosion in the cap part of the gearbox so concentrating my heat there seem to give the best result.  Enjoy your Maramu!

Best,

James