Thanks to all who are trying to help.
Tonight i went back through the steps.
Prop to pump rotation - good
Impeller vane position - good
Correct parts - good
Key in position - good
The impeller definitely getting hot. Steam comes from the telltale just before dying. When i removed the lower unit a small amount of water dripped out and the inside surfaces are wet and a tanish goo. Looks like contaminated oil. Thinking i might have a blockage in the cooling flow.
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