Originally Posted by Miss Rita
When I dropped the rudder I found that there is very little extra room in there. The shaft is 1 1/8", and the housing is just a few thousandths bigger. Mine has upper and lower O-rings, and they seal very well. In other words, you just can't pump more grease into it as you would a wheel bearing; there's no place for it to go.
You can see the tiller arm on top of the shaft, and the clamping bolt on the right side of the picture. The bolt had to be completely removed, not just loosened, before the tiller arm came off.
Sorry that I didn't keep up with this thread, I may have been able to save you a little bit of time. But for others that may venture into this project, here is the link to when I removed my rudder. Like you said, the bolt has to be completely removed from the tiller arm before you can drop the rudder. It's not like a battery clamp. http://www.mastercraft.com/teamtalk/...ghlight=rudder
My rudder box has a small groove cut into the I.D. which allows the grease to be pumped into the box and exit out a small hole in the bottom....provided that the groove is not clogged up with dried up grease. You can see the groove in one of the pictures. I'm not sure which year boats have this set up.