We have a 2005 22i. This spring while cleaning and waxing the bottom I happened to take a look at the shaft and noticed a line where the discoloration on the shaft ended and appeared to go to clean metal. The line is just above the key slot in the first photo. I also noticed that I could see the key which I don't remember noticing before. Does anyone have a measurement from end of shaft to edge of the prop. I've never adjusted the prop on the shaft so I just want to make sure I don't force it too far in one direction or something. I'm thinking of putting a wrench on the nut to push the prop back up the shaft. Couple pictures may help to show what I'm talking about.
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Theoretically, the key should not have an effect on where the prop sits on the shaft. You put the prop on the shaft without the key, mark the shaft, and then adjust the key so that when the key is present the prop still sits in the same place.
Regardless of what is happening now, I would get a new key and do a "fresh install" of your prop as described above. Use a new stainless cotter pin too, and I recommend a thin layer of marine grease where the prop sits against the shaft to ease removal next time around.
Report back on what you find, with more photos please!
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