LOWER UNIT 5 A 791-H GEAR HOUSING

Transcription

1 LOWER UNIT 5 A 791-H GEAR HOUSING

2 Tle of Contents Pge Notes A-1 Drive Shft n Wter Pump Components... 5A-2 Propeller Shft Components A-6 Speil Tools A-8 Removl A-8 Disssemly A-8 Propeller Removl A-8 Drining n Inspeting Ger Housing Lurint A-9 Wter Pump (Design 1) A-10 Wter Pump (Design 2) A-11 Bering Crrier n Propeller Shft A-12 Pinion Ger, Drive Shft, n Forwr Ger A-15 Upper Drive Shft Bering A-16 Oil Sleeve A-17 Lower Drive Shft Bering Re A-17 Shift Shft A-18 Forwr Ger Bering Re A-19 Trim T Ajustment n Replement.. 5A-19 Ressemly A-19 Forwr Ger Bering Re A-19 Shift Shft A-19 Pge Bering Crrier Ressemly A-20 Forwr Ger Ressemly A-22 Propeller Shft Ressemly A-23 Drive Shft Wer Sleeve Instlltion A-23 Lower Drive Shft Bering Re Instlltion A-24 Oil Sleeve Instlltion A-25 Upper Drive Shft Bering Instlltion... 5A-25 Forwr Ger, Lower Drive Shft Bering, Pinion Ger, n Drive Shft Instlltion A-26 Pinion Ger Depth n Forwr Ger Bklsh A-26 Determining Pinion Ger Depth A-26 Determining Forwr Ger Bklsh. 5A-28 Bering Crrier n Propeller Shft Instlltion A-29 Wter Pump Ressemly n Instlltion A-30 Ger Housing Pressure Test A-32 Filling Ger Housing With Lurint A-32 Propeller Instlltion A-33 Instlltion A

3 Notes: LOWER UNIT 5A-1

4 Drive Shft n Wter Pump Components Quiksilver Lurition/Selnt Applition Points C With Teflon ( A12) Lotite 271 (Otin Lolly) 5A-2 LOWER UNIT

5 Drive Shft n Wter Pump Components (Continue) TORQUE REF. NO. QUAN. DESCRIPTION l. in. l. ft. N m 1 1 Drive Shft (Long) Drive Shft (X-Long) 2 1 Shim 3 1 Bering Re 4 1 Tpere Bering 5 1 Wsher 6 1 Srew Wsher 8 1 Srew Wsher 10 1 Srew (Mgneti) Pinion Nut Pinion Ger 13 1 Shift Cm (Letters Fe Up) 14 1 Trim T 15 1 Wsher 16 1 Trim T Bolt Oiler Tue 18 1 Crrier 19 1 Neele Bering (Numers Fe Up) 20 1 Gsket (Not use with nylon over ssy.) 21 1 Oil Sel (Lip Up) 22 1 Oil Sel (Lip Down) 23 1 Cover Assemly 24 1 Gsket 25 1 Fe Plte 26 1 Gsket LOWER UNIT 5A-3

6 Drive Shft n Wter Pump Components (Continue) Quiksilver Lurition/Selnt Applition Points C With Teflon ( A12) Lotite 271 (Otin Lolly) 5A-4 LOWER UNIT

7 Drive Shft n Wter Pump Components (Continue) TORQUE REF. NO. QUAN. DESCRIPTION l. in. l. ft. N m 27 1 Impeller Drive Key 28 1 Impeller 29 1 Wter Pump Assemly 30 1 Wter Tue Sel 31 4 Wter Pump Bolt Delete 33 Delete 34 6 Cover Srew Delete 36 1 Wer Sleeve 37 1 Sel Ring 38 2 Bushing Srew Oil Sel (Lip Up) 40 1 Shift Shft Bushing 41 1 O-Ring 42 1 Shift Shft E Ring 43 1 Shift Shft (Long) 1 Shift Shft (X-Long) 44 1 Ger Housing 45 1 Shift Shft Apter 46 1 Reverse Lok Cm 47 1 Wsher LOWER UNIT 5A-5

8 Propeller Shft Components C With Teflon ( A12) 7 Lotite 271 (Otin Lolly) 5A-6 LOWER UNIT

9 Propeller Shft Components (Continue) TORQUE REF. NO. QUAN. DESCRIPTION l. in. l. ft. N m 1 1 Ger Cse 2 1 Shim 3 1 Bering Re 4 1 Tpere Roller Bering 5 1 Roller Bering 6 1 Forwr Ger 7 1 Cm Follower 8 3 Bll Bering 9 1 Slie Cross Pin 10 1 Spring 11 1 Cluth 12 1 Cluth Cross Pin 13 1 Retiner Spring 14 1 Propeller Shft 15 1 Reverse Ger 16 1 O-Ring 17 1 Thrust Bering 18 1 Thrust Wsher 19 1 Roller Bering 20 1 Bering Crrier 21 1 Wsher 22 1 Nut (Design 2) or Bolt (Design 1) Roller Bering 24 1 Oil Sel (Lip In) 25 1 Oil Sel (Lip Out) 26 1 Thrust Wsher 27 1 Propeller 28 1 T Wsher 29 1 Propeller Nut Stu LOWER UNIT 5A-7

10 Speil Tools Prt No. Desription A1 Puller Jws Puller Bolt A1 Slie Hmmer Mnrel* Mnrel* Driver Ro* Drive Shft Holing Tool Universl Puller Plte M Bering Puller Assemly Mnrel Oil Sel Driver Mnrel Three Ro* Nut* Bklsh Initor Tool (3 Cyl) A1 Dil Initor Dil Initor Aptor Kit A2 Pinion Ger Loting Tool A1 Bering Re Tool A1 Bering Instlltion Tool A1 Wer Sleeve Instlltion Tool A1 Bering Prelo Tool Bering Instlltion Tool Oil Sel Driver Bklsh Initor Tool (4 Cyl) * From Bering Removl n Instlltion Kit ( A5) Removl WARNING To prevent ientl engine strting, remove (n isolte) sprk plug les from sprk plugs efore removing ger housing. 1. Remove (n isolte) sprk plug les from sprk plugs. 2. Shift engine into forwr ger. 3. Tilt engine to full Up position. 4. Remove 4 olts (or loknuts on 1995 Moels) n wshers (two eh sie). 5. Remove loknut n wsher. 6. Remove ger housing. - Bolts (or Loknuts) n Wshers - Loknut n Wsher Disssemly Propeller Removl WARNING If ger housing is not remove from rive shft housing, efore ttempting to remove or instll the propeller, remove (n isolte) sprk plug les from sprk plugs to prevent engine from strting ientlly. 1. Ben ts of t wsher wy from hu. - T Wsher - Hu A-8 LOWER UNIT

11 2. Ple lok of woo, s shown, to prevent propeller from rotting n to protet hns uring removl of nut. 3. Remove nut n pull omponents from shft Oil Level Srew - Fill/Drin Srew - Vent Srew - Blok of Woo Drining n Inspeting Ger Housing Lurint WARNING If ger housing is instlle on engine, to voi ientl strting, isonnet (n isolte) sprk plug les from sprk plugs efore working ner the propeller. 1. With ger housing in norml running position, ple len pn uner housing n remove the two vent srews n one fill/rin srew (with gskets). 2. Inspet ger lurint for metl prtiles (lurint will hve metl flke pperne). Presene of fine metl prtiles (resemling power) on the rin plug r mgnet inites norml wer. The presene of metl hips on the rin plug r mgnet inites the nee for ger housing isssemly n omponent inspetion. 3. Note olor of ger lurint. White or rem olor MAY inite presene of wter in lurint. Ger lurint whih hs een rine from ger se reently in opertion will hve yellowish olor ue to lurint gittion/ertion. Ger lue whih is mixe with ssemly lurint (Speil Lue 101 or 2-4-C w/teflon will lso e remy white in olor. This is norml n shoul not e onfuse with the presene of wter. If wter is supete to e present in gerse, pressure hek of gerse shoul e me (with no lurint in gerse). Gerse shoul hol 10 to 12 psi of pressure for 5 minutes without leking own. Pouring portion of the ger lurint into glss jr n llowing the lurint to settle will llow ny wter in the lue to seprte n settle to the ottom of the jr. 4. Presene of wter in ger lurint inites the nee for isssemly n inspetion of oil sels, sel surfes, O-rings, wter pump gskets s well s ger housing omponents for mge. If gerse is reuilt, gerse shoul e pressure heke efore filling with lurint LOWER UNIT 5A-9

12 Wter Pump (Design 1) 1. If wter tue sel stye on wter tue (insie of rive shft housing) when ger housing ws remove, pull wter tue sel from wter tue. 2. Reple wter tue sel, if mge. 3. Remove 4 olts, wshers, n isoltors. 4. Remove over. e 7. Inspet impeller. Reple impeller if ny of the following onitions exist: Impeller le(s) re rke, torn, or worn. Impeller is glze or melte (use y opertion without suffiient wter supply). Ruer portion of impeller is not one to impeller hu. 8. Remove plte n gsket. 9. Reple plte if groove(s) (other thn impeller seling e groove) in plte re more thn (0.762mm) eep Wter Tue Sel - Bolts (4 eh) - Wshers (4 eh) - Isoltors (4 eh) e - Cover IMPORTANT: The irulr groove forme y the impeller seling e shoul e isregre when inspeting over (Step 5) n plte (Step 9), s the epth of the groove will not ffet wter pump output. 5. Reple over if thikness of steel t the ishrge slots is or less, or if groove(s) (other thn impeller seling e groove) in over roof re more thn (0.762mm) eep. - Plte - Gsket 10. Remove olts n wshers Lift impeller, rive key, n gsket from rive shft Bolts n Wshers (6 eh) Impeller - Drive Key - Gsket 5A-10 LOWER UNIT

13 11. Remove wter pump se. Wter Pump (Design 2) NOTE: Disssemly proeure for DESIGN 2 moel wter pump is the sme s for DESIGN 1 moel wter pump, previous. - Wter Pump Bse 12. Remove (n isr) sels IMPORTANT: Ger housing on 3 CYLINDER MODELS 70, 75, 80, 90 n 4 CYLINDER MODELS 100 n 115 hve een moifie to ept new style plsti wter pump se (P/N 19282A1). This new se oes not require gskets s it hs silione impregnte sel on the top n ottom. As long s this silione sel is not mge i.e., uts or rsions it will retin its seling pilities. This new wter pump se CANNOT BE USED on oler ger housings. The luminum wter pump se (P/N 43055A2) is still ville for use with the oler ger housings. - Sels 13. Remove gsket Wter Pump Cover Gsket - Plsti Pump Bse - Silione Sel (Both Sies) Gsket LOWER UNIT 5A-11

14 Bering Crrier n Propeller Shft 1. Drin lurint from ger housing; refer to Drining n Inspeting Ger Housing Lurint. 2. Remove olts n wshers or self loking nuts if pplile. 5. Lift reverse ger, thrust ering n thrust wsher from ering rrier. 6. Reple reverse ger if ger teeth or luth teeth on reverse ger re hippe or worn. If reverse ger must e reple, pinion ger n sliing luth shoul e inspete for mge. 7. Reple thrust ering n thrust wsher if ruste, pitte or mge. - Bolt n Wshers or Loknuts With propeller shft horizontl, pull rrier to rek sel with ger housing. Remove ering rrier/propeller shft omponents s n ssemly, tking re not to lose m follower or 3 metl lls in en of propeller shft. 4. Remove propeller shft from ering rrier Reverse Ger - Thrust Bering - Thrust Wsher e 8. If ering is ruste or oes not roll freely, reple ering. Remove ering using Slie Hmmer ( A1). - Bering Crrier - Puller Jws ( A1) - Puller Bolt ( ) - Thrust Hu e - Propeller Shft Bering 5A-12 LOWER UNIT

15 9. If ering is ruste or oes not roll freely, reple ering. Remove ering n oil sels using Mnrel* ( ) n Driver Ro* ( ). Disr oil sels. * From Bering Removl n Instlltion Kit ( A5). 11. Remove spring. - Spring Apply onstnt pressure to m follower to prevent m follower ssemly from ejeting from propeller shft while pushing ross pin out of luth og. - Bering - Mnrel ( ) - Driver Ro ( ) Remove (if not remove with ering in Step 9) propeller shft sels n O-ring. - Cross Pin - Cm Follower O-ring LOWER UNIT 5A-13

16 13. Remove omponents from propeller shft. 14. Reple m follower if worn or pitte. 15. Reple sliing luth if jws re roune or hippe. Roune jws inite one or more of the following:. Improper shift le justment.. Engine ile spee too high while shifting.. Shifting from neutrl to reverse (or forwr) too slowly. e 16. Chek ering surfes of propeller shft for pitting or wer. If shft is worn or pitte, reple shft n orresponing ering. 17. Reple propeller shft if ny of the following exist:. Splines re twiste or worn.. Oil sel surfe is groove.. Shft hs notiele wole or is ent more thn in. (0.228mm). Prop shft trueness shoul e mesure with il initor with prop shft on V-loks. f f Cm Follower - 3 Metl Blls - Guie Blok - Spring e - Sliing Cluth f - Jws - V-Bloks - Bering Surfes - Mesure with Dil Initor t this Point A-14 LOWER UNIT

17 Pinion Ger, Drive Shft, n Forwr Ger 1. Hol rive shft using Drive Shft Holing Tool ( ); remove (n isr) pinion nut. 2. Remove rive shft, pinion ger, ering n forwr ger. 3. Reple pinion ger if it is hippe or worn. 4. Reple ering n re if either re ruste or mge; or if ering oes not roll freely. To remove re, refer to Lower Drive Shft Bering Re, following. 5. Reple forwr ger if ger teeth or luth teeth re hippe or worn. 6. Reple ering if it is ruste or oes not roll freely; use punh n hmmer to remove ering. - Bering Reple forwr ger ering n re if either re ruste or mge; or if ering oes not roll freely. Remove ering from ger using Universl Puller Plte ( ) n mnrel. To remove re, refer to Forwr Ger Bering Re, following. e - Drive Shft Holing Tool ( ) - Pinion Nut - Drive Shft - Pinion Ger e - Bering f - Forwr Ger f Forwr Ger Bering - Universl Puller Plte ( ) - Mnrel LOWER UNIT 5A-15

18 8. Reple rive shft if splines re worn or twiste. 9. If ering surfe is mge, reple rive shft n orresponing ering. IMPORTANT: Do not tighten vise ginst rive shft. 10. If wer sleeve is eeply groove llowing wter to enter ger se, remove (n isr) sleeve using Universl Puller Plte ( ) n le hmmer. Upper Drive Shft Bering 1. Reple upper rive shft ering n sleeve if either re rust stine, or if ering will not roll freely. Remove ering n then sleeve using Puller Assemly ( M) with suitle jws. e - Upper Drive Shft Bering - Sleeve - Puller Assemly ( M) Splines - Bering Surfe - Wer Sleeve - Universl Puller Plte ( ) e - Le Hmmer 11. Remove (n isr) ruer ring Ruer Ring 5A-16 LOWER UNIT

19 IMPORTANT: Upper rive shft ering/sleeve must e remove prior to oil sleeve removl. Refer to Upper Drive Shft Bering, preeing. Oil Sleeve 1. Remove oil sleeve (if neessry) using Puller Assemly ( M) with suitle jws. IMPORTANT: Upper rive shft ering/sleeve n oil sleeve o not hve to e remove for lower rive shft ering re removl. Lower Drive Shft Bering Re IMPORTANT: Retin shim(s) for ressemly. 1. Remove re n shim(s) using ering re tool ( A1). - Oil Sleeve - Puller Assemly ( M) Re - Shim(s) - Bering Re Tool ( A1) LOWER UNIT 5A-17

20 Shift Shft 1. Remove shift shft oupler n nylon sper. 4. Remove shift m from housing. 5. Reple shift m if worn Shift Shft Coupler - Sper 2. Remove olts Shift Cm 6. Remove shift shft ushing n lip from shift shft. 7. Reple shift shft if splines re worn or shft is twiste. 8. Remove (n isr) O-ring. e Bolts 3. Remove shift shft ushing n shift shft. - Bushing - Clip - Shift Shft 9. Remove (n isr) sel. - Splines e - O-ring Bushing - Shift Shft Sel 5A-18 LOWER UNIT

21 Forwr Ger Bering Re IMPORTANT: Retin shim(s) for ressemly. 1. Remove re n shim(s) using Slie Hmmer ( A1). - Re - Shim(s) - Slie Hmmer ( A1) Trim T Ajustment n Replement IMPORTANT: The trim t is me of speil lloy to i in proteting the rive shft housing n ger housing from glvni orrosion (orrosion n pitting of metl surfes). Do not pint or ple protetive oting on the trim t, or trim t orrosion protetion funtion will e lost. 1. Reple trim t if 50% (or more) onsume. Mrk lotion of ol trim t on nti-ventiltion plte efore removl; instll new trim t in sme lotion. 2. The trim t provies mens to offset (lne) some of the steering lo tht is use y propeller torque t higher operting spees. If t higher spees the ot turns more esily to the left, loosen olt, move the trim t (triling ege) to the left (when viewe from ehin); retighten olt. Turn trim t (triling ege) to the right if the ot turns more esily to the right. Ressemly Forwr Ger Bering Re 1. Ple shim(s) (retine from isssemly) into housing. If shim(s) were lost, or new ger housing is eing ssemle, strt with (0.254mm) shim(s). 2. Assemle omponents s shown; rive re into housing y striking propeller shft en with le hmmer. e - Shim(s) - Re, Apply Quiksilver Neele Bering Assemly Lurint on O.D. - Mnrel ( ) Shift Shft Disssemle Propeller Shft e - Assemle Bering Crrier 1. Apply Lotite 271 on O.D. of new sel. 2. Press sel into shift shft ushing until sel is flush with surfe. 3. Instll new O-ring. 4. Apply 2-4-C with Teflon on O-ring n I.D. of sel. - Trim T - Anti-Ventiltion Plte - Retining Bolt n Wsher; Torque Bolt to 22 ls. ft. (29.8 N m) Sel - Bushing - Surfe - O-ring LOWER UNIT 5A-19

22 5. Assemle omponents s shown. 8. Apply Lotite 271 on ottom 1/2 of thres of olts; instll olts n torque to 60 l. in. (6.8 N m). - Shift Shft - E Clip - Shift Shft Bushing Instll shift m (numers towr top of ger housing); lign hole in shift m with hole. - Bolts [Torque to 60 l. in. (6.8 N m)] Bering Crrier Ressemly Lurite O.D. of ering n ering rrier ore with Quiksilver 2-4-C w/teflon. 2. Protet lip on forwr sie of ering rrier, using ering instlltion tool ( ). 3. Press propeller shft neele ering (numer sie towr mnrel) into rrier, until ering ottoms out Shift Cm (Numers UP) - Hole 7. Instll shift shft ssemly; insert splines into shift m. - Shift Shft Assemly - Splines Bering Instlltion Tool ( ) - Mnrel ( ) - Suitle Driver Ro A-20 LOWER UNIT

23 4. Ple smller imeter sel on longer shouler of Oil Sel Driver ( ) with sel lip wy from shouler. 5. Protet lip on front sie of ering rrier using Bering Instlltion Tool ( ). Apply Lotite 271 on O.D. of sel. Press sel into rrier until tool ottoms. 8. Instll O-ring. 9. Lurite O-ring with 2-4-C w/teflon. Lurite sel lips with 2-4-C w/teflon ( A12). Lurite outsie imeter of ering with light oting of 2-4-C w/teflon. 10. Press ering into rrier until tool ottoms. - Sel - Oil Sel Driver ( ) - Bering Instlltion Tool ( ) Ple lrger imeter sel on shorter shouler of Oil Sel Driver ( ) with sel lip towr shouler. 7. Protet lip on front sie of ering rrier using Bering Instlltion Tool ( ). Apply Lotite 271 on O.D. of new sel. Press sel into rrier until tool ottoms. - O-ring - Bering, Numere Sie Towr Tool Sel Lips - Bering Instlltion Tool ( ) 11. Instll thrust wsher. Cot thrust wsher with Quiksilver Ger Lurint ( A24). - Sel - Oil Sel Driver ( ) - Bering Instlltion Tool ( ) Thrust Wsher LOWER UNIT 5A-21

24 12. Instll thrust ering. Cot thrust ering with Quiksilver Ger Lurint ( A24). Forwr Ger Ressemly 1. Press ering onto ger (press only on inner re of ering). - Thrust Bering 13. Instll reverse ger Mnrel ( ) - Bering; Lurite I.D. with Quiksilver 2-4-C w/teflon 2. Apply 2-4-Cw/Teflon to ore in enter of ger. 3. Press ering into ger until ering ottoms out. NOTE: Do not pply pressing fore AFTER ering ottoms out s ering mge oul result Reverse Ger Mnrel - Bering, Numere Sie Towr Mnrel 5A-22 LOWER UNIT

25 Propeller Shft Ressemly 1. Instll omponents into propeller shft in sequene shown. Drive Shft Wer Sleeve Instlltion 1. Instll new ruer ring. 2. Apply light ot of Lotite 271 on outsie imeter of ruer ring. - Spring - Guie Blok - 3 Metl Blls* - Cm Follower* *Hol in Ple With Quiksilver 2-4-C w/teflon 2. Instll ross pin Ring 3. Insert sleeve into holer*. *Component of Wer Sleeve Instlltion Tool ( A1). - Apply Pressure in This Diretion - Cross Pin 3. Instll spring. DO NOT overlp springs Sleeve - Holer Spring LOWER UNIT 5A-23

26 4. Press sleeve onto rive shft using Wer Sleeve Instlltion Tool ( A1); ontinue pressing until surfe ontts surfe. Lower Drive Shft Bering Re Instlltion IMPORTANT: Lower rive shft ering up n e instlle with or without upper rive shft ering/sleeve n oil sleeve instlle. 1. Lurite O.D. of ering re with Quiksilver 2-4-C w/teflon. 2. Instll shim(s) n ering re into housing. NOTE: Verify shim(s) re not oke when rwing up re. f e f e Drive Shft - Wer Sleeve Instlltion Tool - Surfe - Surfe 5. Remove exess Lotite from ssemle shft Shim(s); Retine From Disssemly. If Shim(s) Were Lost or New Ger Housing is Being Assemle, Strt With (0.635mm) Shim(s) - Bering Re - Mnrel* - Mnrel* e - Three Ro** ( ) f - Nut** ( ) *From Bering Instlltion Tool ( A1) **From Bering Removl n Instlltion Kit ( A5) 5A-24 LOWER UNIT

27 Oil Sleeve Instlltion 1. Instll oil sleeve with t positione s shown. IMPORTANT: Oil sleeve must e instlle prior to upper rive ering instlltion. IMPORTANT: Upper rive shft ering/sleeve n e instlle with or without lower rive shft ering up instlle. 3. Instll ering/sleeve into housing. f e e f Oil Sleeve -T Upper Drive Shft Bering Instlltion 1. Lurite I.D. of ering holer n O.D. of ering with 2-4-C w/ Teflon. 2. Press ering into sleeve. - Bering/Sleeve - Tpere En - Mnrel* - Mnrel* e - Three Ro** ( ) f - Nut** ( ) *From Bering Instlltion Tool ( A1) **From Bering Removl n Instlltion Kit ( A5) Bering Sleeve - Tpere En - Bering; Numere Sie Towr Mnrel - Mnrel; From Bering Instlltion Tool ( A1) LOWER UNIT 5A-25

28 Forwr Ger, Lower Drive Shft Bering, Pinion Ger, n Drive Shft Instlltion 1. Instll omponents in sequene shown. 2. With ger housing positione up right (rive shft vertil), instll Bering Prelo Tool ( A1) over rive shft in sequene shown. g e h h e f f Forwr Ger/Bering: Work Quiksilver ger lue into ering rollers. - Lower Drive Shft Tpere Roller Bering: Work Quiksilver ger lue into ering rollers. - Pinion Ger - Drive Shft e - Drive Shft Holing Tool ( ) f - Pinion Nut (New): Apply Lotite 271 to thres uring finl ssemly (fter pinion ger epth n forwr ger klsh hve een set), torque to 70 l. ft. (95 N m). Pinion Ger Depth n Forwr Ger Bklsh DETERMINING PINION GEAR DEPTH NOTE: Re entire proeure efore ttempting ny hnge in shim thikness. IMPORTANT: Forwr ger ssemly must e instlle in ger housing when heking pinion ger epth or n inurte mesurement will e otine. 1. Clen the ger housing ering rrier shouler n imeter. - Aptor: Bering surfes len n free of niks - Thrust Bering: Oile n le to move freely - Thrust Wsher: Clen n free of niks n ens - Spring e - Nut: Three ll-the-wy onto olt f - Bolt: Hel snug ginst spring g - Sleeve: Holes in sleeve must lign with set srews h - Set Srew (2): Tightene ginst rive shft, olt shoul not slie on rive shft. 3. Mesure istne () etween top of nut () n ottom of olt he (). 4. Inrese istne () y 1 (25.4mm). 5. Rotte rive shft 5 to 10 revolutions. This shoul properly set upper rive shft tpere roller ering A-26 LOWER UNIT

29 6. Assemly Pinion Ger Loting Tool ( A2) s shown; o not tighten ollr retining olt t this time. e 10. Instll the numer 3 loting is ginst ering rrier shouler in ger housing. 11. Position ess hole s shown. f - Aror - Guging Blok; Instll With Numers Awy From Split Collr - Bolt; Guging Blok Retining - Split Collr e - Bolt; Collr Retining f - Snp Ring 7. Insert tool into forwr ger ssemly; position guging lok uner pinion ger s shown. - Guging Blok Remove tool, tking re not to hnge guging lok position, n tighten ollr retining olt. 9. Insert tool into forwr ger ssemly; position proper numere flt (from hrt) of guging lok uner pinion ger Loting Dis - Aess Hole 12. Determine pinion ger epth y inserting feeler guge thru ess hole in loting is. 13. The orret lerne etween guging lok n pinion ger is (0.64mm). 14. If lerne is orret, leve Bering Prelo Tool on rive shft n proee to Determining Forwr Ger Bklsh, following. 15. If lerne is inorret, (or sutrt) shims from ove ering re to lower (or rise) pinion ger. When reinstlling pinion nut, pply Lotite 271 on thres of nut. MODEL GEAR RATIO (PINION GEAR TEETH/ REVERSE GEAR TEETH) USE FLAT NO. 75-thru-90 (3 Cyliner) 13/ /115/125 (4 Cyliner) 14/ Feeler Guge - Guging Blok - Pinion Ger - Bering Re LOWER UNIT 5A-27

30 DETERMINING FORWARD GEAR BACKLASH NOTE: Re entire proeure efore ttempting ny hnge in shim thikness. 1. Otin orret pinion ger epth; refer to Determining Pinion Ger Depth, preeing. 2. Instll Bering Prelo Tool ( A1) on rive shft; refer to Determining Pinion Ger Depth, preeing. 3. Instll omponents s shown. 5. Instll omponents s shown. e f Propeller Shft* - Bering Crrier* (Assemle) - Puller Jws ( A1) - Puller Bolt ( ); Torque to 45 ls. in. (5.1 N m) *Refer to Bering Crrier n Propeller Shft Instlltion, following. 4. Rotte rive shft 5 to 10 revolutions. This shoul properly set forwr ger tpere roller ering. - Three Ro (Otin Lolly) - Wshers - Nuts - Dil Initor Aptor Kit ( ) e - Dil Initor ( A1) f - Bklsh Initor Tool Position Dil Initor on pproprite line (from hrt) mrke on Bklsh Initor Tool. MODEL 75-thru-90 (3 Cyliner) Bklsh Initor Tool ( ) 100/115/125 (4 Cyliner) Bklsh Initor Tool ( ) ALIGN POINTER OF DIAL INDICATOR WITH MARK 4 1 5A-28 LOWER UNIT

31 7. Lightly turn rive shft k-n-forth (no movement shoul e notie t propeller shft). 8. Dil Initor registers mount of klsh, whih must e etween speifition shown in hrt. MODEL 75-thru-90 (3 Cyliner) 100/115/125 (4 Cyliner) DIAL INDICATOR MINIMUM in. (0.30mm) in. (0.38mm) READING MAXIMUM in. (.48mm) in. (0.55mm) 9. If klsh is less thn the minimum speifition, remove shim(s)* from in front of forwr ger ering re to otin orret klsh. When reinstlling pinion nut, pply Lotite 271 on thres of nut. 10. If klsh is more thn the mximum speifition, shim(s)* in front of forwr ger ering re to otin orret klsh. When reinstlling pinion nut, pply Lotite 271 on thres of nut. * By ing or sutrting (0.025mm) shim, the klsh will hnge pproximtely (.025mm). 3. Lurite o-ring () n res () with 2-4-C w/ Teflon ( A12). 4. Instll ering rrier n propeller shft into housing with the wor TOP lote on flnge (e) towr top of housing. e Bering Crrier n Propeller Shft Instlltion 1. Insert propeller shft ssemly into ering rrier. 2. Before instlling ering rrier ssemly into ger housing, otin lolly 6 (152.4mm) long y 1-1/4 1-1/2 ( mm) imeter piee of PVC pipe. Instll the PVC pipe (f) over the prop shft () n seure the pipe ginst the ering rrier ssemly () with the propeller nut (g) n t wsher (h). This will llow the reverse ger to pply pressure to the reverse ger thrust ering to prevent the thrust ering from eing invertently isloge s the ering rrier ssemly is instlle in the ger housing. f g 5. Instll omponents s shown e h Wshers - Bolts; Apply Lotite 271 on Thres n Torque to 21.7 l. ft. (29.4 N m) NOTE: If nuts re use in ple of olts (), torque nuts to 21.7 l. ft. (29.4 N m) LOWER UNIT 5A-29

32 Wter Pump Ressemly n Instlltion 6. Ple sel on longer shouler sie of Oil Sel Driver ( ) with sel lip wy from shouler. 7. Apply Lotite 271 on O.D. of sel; press sel into wter pump se until tool ottoms. TEFLON COATED LIP - FLAT BROWNISH BLACK COLOR - LIP FACES TOWARD POWER HEAD 8. Ple sel on shorter shouler sie of Oil Sel Driver ( ) with sel lip towr shouler. 9. Apply Lotite 271 on O.D. of sel; press sel into wter pump se until tool ottoms. 10. Lurite lip of eh sel with Quiksilver 2-4-C w/ Teflon ( A12). LIP FACES TOWARD GEAR CASE - GLOSS BLACK COLOR SPRING - FACES TOWARD POWER HEAD SPRING - FACES TOWARD GEAR CASE - Sel - Oil Sel Driver ( ) Sel - Oil Sel Driver ( ) 11. Instll gsket Gsket A-30 LOWER UNIT

33 12. Instll omponents s shown. 15. Lurite I.D. of over with Quiksilver 2-4 C w/ Teflon ( A12). 16. Rotte rive shft lokwise n push over own over impeller. 17. Instll over. 18. If wter tue sel stye on wter tue (insie of rive shft housing) when ger housing ws remove, pull wter tue sel from wter tue. 19. Lurite I.D. of wter tue sel with Quiksilver 2-4-C w/teflon ( A12) n instll s shown. - Wter Pump Bse - Bolts n Wshers; Apply Lotite 271 on Thres n Torque to 60 l. in. (6.8 N m) e 13. Instll gsket n plte Gsket - Plte IMPORTANT: If the ol impeller will e re-use, impeller must e instlle in originl (lokwise) iretion of rottion. 14. Instll gsket, rive key n impeller. - Cover - Isoltors (4) If Equippe - Wshers (4) - Bolts (4); Apply Lotite 271 on Thres n Torque to 60 l. in. (6.8 N m). e - Wter Tue Sel NOTE: It is reommene tht the gerse e pressure teste for leks fter ressemly n BEFORE ger lue is e. Gerse shoul hol 10 to 12 psi for 5 minutes Gsket - Drive Key - Impeller LOWER UNIT 5A-31

34 Ger Housing Pressure Test 1. Remove vent plug n instll pressure test guge Filling Ger Housing With Lurint NOTE: Ger housing lurint pity is 22.5 fl. oz. (665.2ml). WARNING If ger housing is instlle on engine, to voi ientl strting, isonnet (n isolte) sprk plug les from sprk plugs efore working ner the propeller. 2. Pressurize housing to 10 to 12 psi n oserve guge for 5 minutes. 3. Rotte rive shft,prop shft n move shift shft while housing is pressurize to hek for leks. CAUTION Do not use utomotive grese in the ger housing. Use only Quiksilver Ger Lue or Quiksilver Super-Duty Lower Unit Lurint. 1. Remove ny gsket mteril from Fill n Vent srews n ger housing. 2. Instll new gskets on Fill n Vent srews. IMPORTANT: Never pply lurint to ger housing without first removing Vent srews or ger housing nnot e fille euse of trppe ir. Fill ger housing only when housing is in vertil position. 3. Remove lurint Fill srew n gsket from ger housing. 4. Insert lurint tue into Fill hole, then remove Vent srews n gskets. 5. Fill ger housing with lurint until exess strts to flow out of one (first) Vent srew hole. 6. Reple this lurint Vent srew n gsket only n ontinue filling until exess strts to flow out of seon lurint Vent srew hole. 4. If pressure rop is note, immerse housing in wter. 5. Re-pressurize to 10 to 12 psi n hek for ir ules. 6. Reple leking sels s neessry. Retest housing. Note: Gerse shoul hol 10 to 12 psi for 5 minutes. 7. Remove tester from housing n instll vent plug Vent Srew - Fill/Drin Srew - Oil Level Vent Srew 5A-32 LOWER UNIT

35 7. Reple seon lurint Vent srew n gsket. IMPORTANT: Do not lose more thn one flui oune (30) of ger lurint while reinstlling FILL srew. 8. Remove lurint tue from Fill hole; instll Fill srew n gsket. Propeller Instlltion WARNING If ger housing is not remove from rive shft housing, efore ttempting to remove or instll the propeller, remove (n isolte) sprk plug les from sprk plugs to prevent engine from strting ientlly. 1. Apply lierl ot of one of the following Quiksilver prouts on propeller shft splines: Speil Lurint 101 (P/N A1) 2-4-C w/teflon ( A12) Anti-Corrosion Grese ( A24) 2. Instll omponents s shown Thrust Hu; Flt Surfe Towr Propeller - Propeller 3. Instll t wsher n loknut. 4. Thre loknut onto propeller shft until loknut is reesse into t wsher. 5. Torque loknut to 55 ls. ft. (75 N m). 6. Ben 3 ts of t wsher own into grooves to seure loknut. If t wsher ts o not lign with slots, ontinue to tighten loknut to otin lignment. CAUTION Do not misinterpret propeller shft movement with propeller movement. If propeller n propeller shft together move forwr-n-ft, this is norml; however, propeller shoul not move forwr-n-ft on propeller shft. 7. After first use, retighten propeller nut n gin seure with t wsher. Propeller shoul e heke perioilly for tightness, prtiulrly if stinless steel propeller is use. - T Wsher - Loknut - Grooves Instlltion WARNING Disonnet (n isolte) sprk plug les from sprk plugs efore instlling ger housing onto rive shft housing. Filure to follow this wrning oul result in ientl engine strting n possile injury. 1. Position shift lok in forwr ger position, s shown Shift Blok; Front of Blok MUST Exten 1/8 (3.2mm) Pst Front of Ril. - Ril 2. Tilt engine to full up position n engge tilt lok lever. 3. Shift ger housing into neutrl position. Propeller shft will rotte freely in either iretion LOWER UNIT 5A-33

36 4. Instll wter tue sel; lue I.D. of sel with Quiksilver 2-4-C w/teflon ( A12). 5. Apply e of RTV Seler s shown. 8. Instll omponents s shown in pproprite photo Wter Tue Sel - RTV Seler CAUTION Do not use lurint on top of rive shft. Exess lurint, tht is trppe in lerne spe, will not llow rive shft to fully engge with rnkshft. Susequently, tightening the ger housing fsteners (while lurint is on top of rive shft) will lo the rive shft/rnkshft n mge either or oth the power he n ger housing. Top of rive shft is to e wipe free of lurint. 6. Apply light ot of Quiksilver 2-4-C w/teflon onto rive shft splines. 7. Apply light ot of Quiksilver 2-4-C w/teflon on ger se shift shft splines n upper shift shft splines. Do not use lurint on ens of shift shfts Nylon Sper - Shift Shft Coupler; Use on Moels Equippe with Power Trim Nylon Sper - Shift Shft Coupler; Use on Moels NOT Equippe with Power Trim - Flt; MUST BE Positione Towr Front of Ger Housing. 9. Shift ger housing into forwr ger position. In forwr ger the ger housing will rthet when propeller shft is turne lokwise n resistne will e felt when propeller shft is rotte ounterlokwise. 10. Apply Lotite Gre 271 on thres of ger housing retining olts. 5A-34 LOWER UNIT

37 NOTE: If, while performing Step 11, the rive shft splines will not lign with the rnkshft splines, ple propeller onto propeller shft n turn it ounterlokwise s the ger housing is eing pushe towr rive shft housing. NOTE: During instlltion of ger housing, it my e neessry to move the shift lok (lote uner owl) slightly to lign upper shift shft splines with shift shft oupler splines. 11. Position ger housing so tht the riveshft is protruing into rive shft housing. 12. Move ger housing up towr rive shft housing, while ligning upper shift shft splines with shift shft oupler splines, wter tue with wter tue sel, n rnk shft splines with rive shft splines. 13. Instll 4 olts n wshers (two eh sie). 14. Instll loknut n wsher. 15. Torque olts n loknut (or nuts only if pplile) to 40 ls. ft. (54 N m). 16. Chek shift opertion s follows:. Ple shift lever in forwr ger. Ger housing shoul rthet when propeller shft is turne lokwise n resistne shoul e felt when propeller shft is turne ounterlokwise.. Ple shift lever in neutrl. Propeller shft shoul rotte freely in either iretion.. While rotting propeller shft, ple shift lever in reverse ger. Resistne shoul e felt when propeller shft is rotte in either iretion. IMPORTANT: If shift opertion is not s esrie, preeing, the ger housing must e remove n the use orrete Bolts n Wshers (4) - Loknut n Wsher LOWER UNIT 5A-35