For GTR experts. Its the old style lower. See below pic for reference, then help if you can and would like to by telling me what's missing from the shaft assembly. That visible part of the sleeve is 7/16". It overlaps the hex by a good bit, and I can barely engage the nylock part of the prop nut.

Edit: whatever it is isn't missing, it's additional. That sleeve is overhanging the hex, so it's sticking out too far, it's not the whole shaft sticking out too far.

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I have the same lower unit. That gap shouldn't be more than 1/16". Looks like the rear bushing has worked it's way out, which is what's keeping your nut from starting on the shaft, because your prop's not all the way on. Not an expert by any means, but you may be able to tap the prop with a rubber mallet and tap it back in. I would contact GT (talk to Hoytt or Brett) and get their input as to why it's backed out. I've never had mine apart, so I'm no help on why it happened. Hope it ain't anything too serious.

Let us know what you find out. Just out of curiosity, is your lower unit making any grinding noises when you turn the prop? Do you have any play in the shaft (in/out or up/down)? What does your grease look like?

No noise. No play. Clean as grease should be.

Have you tried tapping it back in?

I tried tightening the nut with a washer and prop. It doesn't budge.

I've noticed mine slipping out once before, but it slid right back in. You may want to give them a call tomorrow. Sounds like your bushing may have a burr or something keeping it from retracting back in. Again, hopefully it isn't too serious bro.

Anyone have an idea what it's gonna cost me to redo the seals, bearings, and anything else on a gtr if the shaft is still in good shape? I got a sneaking suspicion I'm gonna pull this thing apart tomorrow or tuesday night and some things isn't gonna be ok. With everything else I've found to date, and the story I got on the front end when I bought it, something isn't adding up, and it's got to come completely apart now to figure out what. May as well plan to replace the guts while it's broken down so I know it can be trusted.

I think I saw someone post here recently that a seal/bearing kit from GT was $125 if your shaft doesn't need replacement. Believe shaft is another $150. Fingers crossed for you dude. I've felt your frustration.

The upper pulley/ taper lock is what locates the shaft. I would pull the LU and inspect it to see if the but is still on the end of the shaft.

Apparently sending to gt. He said something ain't right, ship it to me.
Dammit.

If your taper lock is correctly installed like you are describing something is up. The spacer your refereeing too near the prop is a wear sleeve. It sits up against the Torrington bearing race and the shaft seal rides on that. Like I mentioned previously the Taperlock and the Nut on the end of the shaft is what holds the whole shaft together to keep it LOCATED.

Unless I could take it apart then I could tell you what's up. GT will fix you up!

We're on the same page. Apparently it's the wrong sleeve according to who I got it from. It's already in a box to go to gt.

Yes there are 2 different size sleeves on that shaft.

So, here's my question. Send it to gt and pay whatever that's gonna wind up costing, or try the other sleeve? Gt didn't mention there was a different sleeve that's 3/8" longer, or any other option. I'm not an expert mechanic, but I have managed to rebuild this engine and fix some issues with this frame all by my lonesome with people answering questions I've had along the way. The shipping alone is a heck of an investment if the sleeve is wrong and that's it.

How long are the two sleeves? I can pull and measure what I have to eliminate or confirm that as the problem.

OK ill walk through the rear section of the shaft. The bearing housing holds the 2 seals, and the Torrington bearing. The rear shaft holds the bearing race that is up against a machined step in the shaft, then 2 o rings ride behind the race in 2 grooves (seals wear sleeve to shaft), wear sleeve buts against the race, then the whole bearing housing assembly slips over the race and wear sleeve.