LOWER UNIT. Table of Contents. Specifications. Section 6 Gear Housing

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1 Tle of Contents LOWER UNIT Setion 6 Ger Housing GEAR HOUSING Speifitions Speil Tools Ger Housing (Drive Shft)(2.00:1 Ger Rtio) Ger Housing (Propeller Shft)(2.00:1 Ger Rtio) Gerse Removl Gerse Disssemly Propeller Removl Drining n Inspeting Ger Lurint Bering Crrier Propeller Shft Wter Pump, Drive Shft n Shift Shft Pinion Ger n Forwr Ger Drive Shft Bushing, Bering n Lurition Sleeve Aluminum Anoe n Wter Inlet Ressemly Drive Shft Neele Bering, Bushing n Lurition Sleeve Instlltion Speifitions Forwr Ger Bering Re Instlltion Forwr Ger Ressemly Bering Crrier Ressemly Wter Pump Bse n Shift Shft Ressemly Propeller Shft Ressemly Forwr Ger, Pinion Ger n Drive Shft Instlltion Shift Shft n Wter Pump Bse Instlltion Wter Pump Cover Ressemly Impeller n Pump Cover Instlltion Propeller Shft n Bering Crrier Instlltion Aluminum Anoe n Wter Inlet Instlltion Propeller Instlltion Filling Ger Housing with Lurint Instlltion GEAR HOUSING Ger Rtio Gerse Cpity Lurint Type Forwr Ger - No. of Teeth-Type Pinion Ger - No. of Teeth-Type Pinion Height Forwr Ger Bklsh Reverse Ger Bklsh Wter Pressure With Ile W/O Ile 2.0:1 6.8 fl. oz. (200 ml) Quiksilver Ger Lue Premium Blen 26 Spirl/Bevel 13 Spirl/Bevel Floting No Ajustment No Ajustment RPM 1/2 1-1/2 750 RPM RPM RPM NOTE: Telltle t IDLE my e intermittnt on engines with thermostts instlle R1 MAY 1998 Pge 6-1

2 Speil Tools 1. Universl Puller Plte Puller Assemly M n Puller Plte Puller Plte Slie Hmmer A1 4. Bering Crrier Tool Drive Shft Bering Removl Tool A1 -Drive Shft Bushing Removl Tool Drive Shft Bushing Instlltion Tool A1 -Drive Shft Bering Instlltion Tool Pge R1 MAY 1998

3 7. Mnrel GEAR HOUSING 8. Bushing Removl Tool Sel Instlltion Tool A1 -Sel/Bushing Instlltion Tool Expning Ro (SNAP ON P/N CG40-4)* 11. Collet (Jws) (SNAP ON P/N CG40-15)* 12. Lekge Tester FT80 *Purhse From: SNAP ON TOOLS Corportion th Street Kenosh, Wi R1 MAY 1998 Pge 6-3

4 Ger Housing (Drive Shft)(2.00:1 Ger Rtio) 2.60 IN./102MM TORPEDO DIA Lotite 271 ( ) 85 RTV 587 Silione Seler ( ) 87 Quiksilver Ger Lurint ( A24) C With Teflon ( A12) Pge R1 MAY 1998

5 Ger Housing (Drive Shft)(2.00:1 Ger Rtio) GEAR HOUSING TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 GEAR HOUSING(BLACK-SHORT) 1 GEAR HOUSING(BLACK-LONG) 1 1 GEAR HOUSING(BLACK-BASIC) 2 1 BUSHING ger housing 3 1 DRAIN SCREW 4 1 SEALING WASHER 5 1 SLEEVE ASSEMBLY 6 1 SLEEVE 7 1 BUSHING 8 1 SCREW PLUG KIT 9 1 SEALING WASHER 10 1 SCREEN 11 1 SCREW ANODE ASSEMBLY 13 1 SCREW SEAL 15 1 PINION GEAR (13 TEETH) 16 1 WASHER thrust 17 1 BEARING 18 1 WATER PUMP BASE 19 1 GASKET 20 1 SEAL 21 1 RETAINER 22 1 SCREW (10-16 x 1/2) Drive Tight 23 1 QUAD RING 24 2 OIL SEAL 25 1 GASKET 26 1 WATER TUBE 27 1 FACE PLATE 28 1 COVER ASSEMBLY 29 1 INSERT 30 1 SEAL 31 1 IMPELLER 32 1 KEY ASSEMBLY 33 2 WASHER 34 1 GUIDE 35 5 SCREW wter pump (M6 x 30) CAM shift 1 SHIFT SHAFT (SHORT) 37 1 SHIFT SHAFT (LONG) 38 1 E-RING 39 2 GUIDE 40 1 SCREW (M5 x 25) NUT guie srew DRIVE SHAFT (SHORT) 42 1 DRIVE SHAFT (LONG) 43 1 THRUST WASHER R1 MAY 1998 Pge 6-5

6 Ger Housing (Propeller Shft)(2.00:1 Ger Rtio) IN./102MM TORPEDO DIA Lotite 271 ( ) 87 Quiksilver Ger Lurint ( A24) 94 Anti-Corrosion Grese ( A6) 2-4-C With Teflon ( A12) Pge R1 MAY 1998

7 Ger Housing (Propeller Shft)(2.00:1 Ger Rtio) GEAR HOUSING REF. TORQUE NO. QTY. DESCRIPTION l. in. l. ft. N m 1 GEAR HOUSING(BLACK-SHORT) 1 GEAR HOUSING(BLACK-LONG) 1 1 GEAR HOUSING (BLACK-BASIC) 44 1 ROLLER BEARING 45 1 CUP 46 1 FORWARD GEAR (26 TEETH) 47 1 BUSHING 48 1 CAM FOLLOWER 49 1 CLUTCH ASSEMBLY 50 1 CROSS PIN 51 1 SPRING 52 1 PROPELLER SHAFT 53 1 REVERSE GEAR (26 TEETH) 54 1 BEARING CARRIER O-RING 56 1 BUSHING 57 1 OIL SEAL 58 1 OIL SEAL 59 1 SCREW (M8 x 50) SCREW (M8 x 30) PROPELLER (9-1/4 IN. x 7 IN.) 61 1 PROPELLER (9 IN. x 9 IN.) 1 PROPELLER (9-3/4 IN. x 6-1/2 IN.) 62 1 SPACER 63 1 PROPELLER NUT THRUST HUB 65 1 HI-REVERSE THRUST CUP R1 MAY 1998 Pge 6-7

8 Gerse Removl WARNING To prevent ientl engine strting, remove (n isolte) sprk plug les from sprk plugs BEFORE removing ger housing. 1. Remove (n isolte) sprk plug les from sprk plugs. 2. Shift outor into FORWARD ger. 3. Tilt outor to full UP position. 4. Remove shift shft retiner. -Retiner 5. Remove reverse lok tutor. 6. Remove 3 olts Atutor -Bolts (3) Pge R1 MAY 1998

9 Gerse Disssemly GEAR HOUSING Propeller Removl WARNING If ger housing is NOT remove from rive shft housing, remove (n isolte) sprk plug les from sprk plugs to prevent outor from ientlly strting while removing n instlling propeller. 1. Ple lok of woo etween nti-ventiltion plte n propeller to prevent propeller from turning n to protet hns while removing prop. 2. Remove nut, thrust hus n propeller. -Woo -Nut -Thrust Hus Drining n Inspeting Ger Lurint Remove oth VENT n FILL srews with gskets. 2. Inspet ger lurint for metl prtiles. Presene of smll mount of fine metl prtiles (resemling power) inites norml wer. Presene of lrge prtiles (hips) or lrge quntity of fine prtiles inites nee for ger housing isssemly n omponent inspetion. 3. Note olor of ger lurint. White or rem olor inites presene of wter in lurint. NOTE: When rining ger se for the first time, lurint my pper rem olore ue to the mixing of ssemly lurint n ger lurint. This is NOT n inition of wter intrusion. If, uring susequent rining of ger se, lurint ppers rem olore or milky, wter my e present. Ger se shoul e isssemle n ll gskets, sels n o-rings reple. Inspet ll omponents for wter mge R1 MAY 1998 Pge 6-9

10 4. Chek rin pn for wter seprtion from lurint. Presene of wter in ger lurint inites the nee for isssemly n inspetion of oil sels, sel surfes n ger housing omponents. Bering Crrier -Vent Srew -Fill Srew Remove ering rrier (LEFT HAND thre) using Bering Crrier Tool ( ) Remove rrier n propeller shft ssemly from housing. NOTE: Cm follower is free to slie out of propeller shft. -Cm Follower Pge R1 MAY 1998

11 3. Remove propeller shft n REVERSE ger from ering rrier. 4. Reple REVERSE ger if ger teeth or luth teeth re hippe or worn. NOTE: When using punh to remove rrier sels, e reful to not to sr rrier sel surfe with punh. If rrier sel surfe is mge, reple rrier. 5. Using suitle punh, remove oth sels from ering rrier. e Ger Teeth -Cluth Teeth -Oil Sel -Fish Line Cutter Sel e -Punh 6. Reple ering rrier ushing if ushing or re on propeller shft tht ushing ontts is pitte or worn. Press ushing from rrier using Bushing Removl Tool ( ) Bushing -Mnrel ( ) R1 MAY 1998 Pge 6-11

12 Propeller Shft 1. Inspet m follower for wer. If m follower is worn, reple follower n inspet shift m for servieility. Reple m if worn. -Cm Follower 1. Remove groove pin from luth/propeller shft pplying pressure to sie of pin tht is NOT groove. Disr pin. -Punh -Groove Pin (Disr) 2. Remove spring n sliing luth Spring -Cluth 3. Reple luth if jws re roune or hippe. Roune jws my e use y the following:. Improper shift le justment.. Engine ile spee too high while shifting.. Shifting too slowly from NEUTRAL into FORWARD or REVERSE Pge R1 MAY 1998

13 4. Inspet ushing surfes of propeller shft for pitting or wer. Reple shft n orresponing ushing if wer or pitting is oserve. 5. Reple 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. (0.15mm) Bushing Surfes -Oil Sel Surfe -Mesure Here for Wole (When mesuring shft for wole, use v-loks n support t ushing surfe) Wter Pump, Drive Shft n Shift Shft 1. Remove 4 olts from pump over. 2. Remove over, nylon wshers (ove n elow impeller), impeller n rive key from rive shft. 3. It is reommene tht impeller e reple whenever ger se is eing servie. NOTE: If impeller is not going to e reple, DO NOT instll impeller in reverse rottion to its originl stte s vnes hve tken set. Vnes will rk n rek shortly fter outor is returne to servie. e -Cover -Nylon Wsher -Impeller -Nylon Wsher e -Key R1 MAY 1998 Pge 6-13

14 4. Remove guie from over. 5. Reple ruer sel if mge. 6. Reple over if insie is groove. 7. Remove plte, gsket, qu-ring, olt n wsher. 8. Reple plte if groove. f e Guie -Sel -Plte -Gsket (Disr) e -Qu-Ring f -Bolt n Wsher 9. Reple sel if mge. 10. Remove wter pump se n shift shft from housing. 11. Remove gsket Sel -Pump Bse -Shift Shft -Gsket (Disr) Pge R1 MAY 1998

15 12. Inspet shift m for wer. Reple if worn. GEAR HOUSING Shift Cm 13. Remove lip from shift shft. Unthre shift m. Remove shft from wter pump se Clip -Shift Cm 14. Remove srew n pull wter tue from se Srew -Wter Tue 15. Reple sel if mge. Reple wter tue if orroe. -Sel -Wter Tue R1 MAY 1998 Pge 6-15

16 16. Remove rive shft from ger housing. NOTE: Thrust wshers, pinion ger n forwr ger ssemly re free to fll from housing when rive shft is remove Thrust Wsher (without oil groove) -Thrust Wsher (with oil groove groove fes own) -Pinion Ger -Forwr Ger Assemly 17. Inspet ering/ushing surfes of rive shft for pitting or wer. If shft is pitte or worn, reple shft n orresponing ering/ushing. 18. Reple rive shft if the following exist:. Splines re twiste or worn.. Oil sel surfe is groove. 19. Using srew river or punh, refully remove (n isr) sels from pump se Bushing Surfe -Bering Surfe -Sel Surfe -Sels Pge R1 MAY 1998

17 Pinion Ger n Forwr Ger PINION GEAR GEAR HOUSING 1. Inspet pinion ger teeth for rekge, rust, hipping or exessive wer (teeth re shrpe ege). 2. If pinion ger teeth re mge, inspet FORWARD n REVERSE ger for mge. 3. Reple gers s require. FORWARD GEAR -Pinion Ger Inspet forwr ger teeth for rekge, rust, hipping n exessive wer (teeth re shrpe ege). 2. Inspet forwr ger luth jws for wer. Roune jws inite the following:. Improper shift le justment.. Engine ile spee too high.. Shifting too slowly Ger Teeth -Cluth Jws 3. Inspet propeller shft FORWARD ger ushing surfe to etermine onition of ushing. If surfe is isolore (from lk of lurint), pitte or worn, propeller shft n ushing shoul e reple. -Bushing -Bushing Surfe R1 MAY 1998 Pge 6-17

18 4. If neessry, press ushing from ger using Bushing Removl Tool Bushing -Bushing Removl Tool ( ) IMPORTANT: If FORWARD ger tpere ering or re requires replement, reple ering n re s set. NOTE: DO NOT remove tpere ering from FORWARD ger unless replement is neessry s removl proess will mge ering. 5. Inspet FORWARD ger tpere ering n re for rust, roughness or exessive wer (looseness). 6. If ering is in serviele onition, DO NOT remove ering from ger s removl proess will mge ering. 7. If ering must e reple, remove ering from ger using Universl Puller Plte ( ) n suitle mnrel (5/8 in. soket) -Bering -Universl Puller Plte ( ) -Mnrel (5/8 in. Soket) Pge R1 MAY 1998

19 8. Reple FORWARD ger re if it is ruste or mge or if FORWARD ger tpere ering must e reple. Remove re from housing using Bering Puller Assemly ( M) n Puller Plte ( ) Re -Bering Puller Assemly ( M) -Puller Plte ( ) Drive Shft Bushing, Bering n Lurition Sleeve Inspet rive shft ushing n ering surfe to etermine onition of orresponing upper rive shft ushing n lower rive shft neele ering. If rive shft surfe is ruste, pitte, isolore (lue lk of lurition) or worn; reple rive shft n orresponing ushing/ering. DO NOT remove ushing or ering if replement is not neessry Bushing Surfe -Bering Surfe -Upper Drive Shft Bushing -Lower Drive Shft Neele Bering IMPORTANT: If upper rive shft ushing or lower rive shft neele ering pper to e spinning in their respetive ores, the ger housing shoul e reple R1 MAY 1998 Pge 6-19

20 2. To reple upper rive shft ushing, use Snp On* Expning Ro (CG 40-4) Snp On Collet (CG 40A6) Slie Hmmer ( A1) *Purhse from: Snp On Tools Corportion th Street Kenosh, WI CG 40-4 CG 40A Expning Ro (CG 40-4) -Collet (CG 40A6) -Slie Hmmer ( A1) -Bushing 3. To gin ess to lower rive shft neele ering, remove lurition sleeve. NOTE: When upper rive shft ushing is instlle, urr my e forme preventing the removl of the lurition sleeve. Use knife to remove urr. 4. Remove neele ering using Drive Shft Bering Removl Tool ( A1) A Lurition Sleeve -Neele Bering -Driver Ro -Pilot Pge R1 MAY 1998

21 Aluminum Anoe n Wter Inlet 1. Reple luminum noe if more thn 50% onsume. 2. Remove wter inlet n hek tht holes re not ostrute. GEAR HOUSING -Aluminum Anoe -Wter Inlet Ressemly Drive Shft Neele Bering, Bushing n Lurition Sleeve Instlltion 1. Instll lower rive shft neele ering (numers/letters fe own) using Drive Shft Bushing Tool ( A1) e f -Puller Bolt -Flt Wsher -Wfer Bering -Pilot e -Neele Bering f -Mnrel A R1 MAY 1998 Pge 6-21

22 2. Instll lurition sleeve Sleeve 3. Instll upper rive shft ushing ssemly using Drive Shft Bushing Tool ( A1). NOTE: The upper rive shft ushing is presse into sleeve. If the ushing is not worn into the sleeve or the ushing is not spinning within the sleeve, the ushing lone my e reple. Press the new ushing into the sleeve using suitle mnrel. If the sleeve is mge, the ushing/sleeve ssemly must e reple e f Puller Bolt -Flt Wsher -Wfer Bering -Pilot e -Bushing/Sleeve f -Mnrel A1 Pge R1 MAY 1998

23 Forwr Ger Bering Re Instlltion Instll re into housing using Mnrel ( ) n Bering Crrier Tool ( ) Re -Mnrel ( ) -Bering Crrier Tool ( ) Forwr Ger Ressemly Instll ushing n ering using Mnrel ( ) n press Mnrel ( ) -Bushing -Bering R1 MAY 1998 Pge 6-23

24 Bering Crrier Ressemly 1. Apply Quiksilver Ger Lurint to ushing n press ushing into rrier using Mnrel ( A1). 2. Apply Lotite 271 to O.D. of sel n with lip fing ushing, press sel into rrier using Mnrel ( A1) A A f e Quiksilver Ger Lurint ( A24) 7 Lotite 271 ( ) -Bushing -Mnrel ( A1) -Mnrel ( A1) -Ring (use with mnrel) e -Sel (LIP FACES BUSHING) f -Bushing 3. Apply Lotite 271 to O.D. of fishline utter sel. With ring remove from Mnrel ( A1), press sel, with LIP FACING Mnrel, into rrier. Apply 2-4-C w/teflon Mrine Lurint etween lips of oth sels. 4. Apply 2-4-C w/teflon Mrine Lurint to o-ring n instll o-ring on rrier A Lotite 271 ( ) 2-4-C With Teflon ( A12) -Fishline Cutter Sel (LIP FACES MANDREL) -Mnrel (without Ring A1) -O-ring Pge R1 MAY 1998

25 Wter Pump Bse n Shift Shft Ressemly 1. Apply Lotite 271 to O.D. of sel. With lip of sel fing DOWN, push sel into se using Mnrel ( ). 2. Apply Lotite 271 to O.D. of sel. With sel lip fing UP, push sel into se using Mnrel ( ). Apply 2-4-C w/teflon etween lips of oth sels Lotite 271 ( ) -Sel (Lip FACES DOWN) -Mnrel ( ) -Sel (Lip FACES UP) -Mnrel ( ) 3. Instll sel onto wter tue. 2-4-C With Teflon ( A12) 4. Seure wter tue to pump se with retiner n srew. -Sel -Pump Bse -Wter Tue -Retiner e -Srew e R1 MAY 1998 Pge 6-25

26 5. Instll shift shft through pump se. 6. Instll E-lip on shift shft. Clip must e elow pump se. 7. Thre shift m onto shft. -E-lip -Shift Cm Propeller Shft Ressemly 1. Slie luth onto propeller shft Sliing Cluth -Short En (FORWARD Ger Sie) -Hole (must lign with slot) -Slot 2. Insert m follower spring into shft Spring Pge R1 MAY 1998

27 3. Compress spring n instll NEW groove pin. e GEAR HOUSING Vise -Srewriver or smll Punh -Spring -Groove Pin (Press in until Flush) e -Serrtions 4. Apply 2-4-C w/teflon to m follower (flt sie) n instll follower into shft Cm Follower -Flt Sie Forwr Ger, Pinion Ger n Drive Shft Instlltion Instll FORWARD ger ssemly into forwr ger re. 2. Instll rive shft through upper rive shft ushing, oil sleeve n lower rive shft neele ering. 3. While lifting rive shft slightly, instll lower thrust wsher (GROOVED SIDE FACES DOWN) n PINION ger. It my e neessry to rotte rive shft slightly to engge pinion ger with splines of rive shft n with forwr ger teeth. 4. Instll upper thrust wsher ove upper rive shft ushing. g e -FORWARD Ger Assemly -Drive Shft Bushing -Oil Sleeve -Neele Bering f 529 e -Lower Thrust Wsher (GROOVED SIDE FACES DOWN) f -Pinion Ger g-upper Thrust Wsher R1 MAY 1998 Pge 6-27

28 Shift Shft n Wter Pump Bse Instlltion 1. Apply 2-4-C w/teflon to I.D. of sel. 2. Instll sel in housing with tpere en fing up. 3. Instll se gsket with rin hole positione s shown C With Teflon ( A12) -Sel -Tpere I.D. -Bse Gsket -Hole IMPORTANT: Verify sel is not pushe out of position when wter tue is instlle. 4. Slie wter pump se with shift shft own rive shft. Align wter tue with sel in housing while seting wter pump se. e -Shift Shft -Shift Cm (POSITION AS SHOWN) -Pump Bse -Wter Tue e -Sel Pge R1 MAY 1998

29 5. Apply 2-4-C w/teflon to I.D. n O.D. of shift shft qu ring. Set qu ring in pump se. 6. Apply Lotite 271 to olt thres n seure pump se to housing with olt n wsher. Torque olt to 50 l. in. (5.6 N m). 7. Instll gsket n fe plte. 7 7 Lotite 271 ( ) C With Teflon ( A12) -Qu Ring -Bolt n Wsher [Torque to 50 l. in. (5.6 N m)] -Gsket -Fe Plte Wter Pump Cover Ressemly 1. Apply 2-4-C w/teflon to O.D. of sel n sel surfe. 2. Instll sel into over. 3. Ple wter tue guie onto sel C With Teflon ( A12) -Sel -Sel Surfe -Guie R1 MAY 1998 Pge 6-29

30 Impeller n Pump Cover Instlltion 1. Instll neoprene wsher. 2. Instll rive key. Use 2-4-C w/teflon to hol key to rive shft. IMPORTANT: It is reommene tht the impeller e reple regrless of pperne. If impeller must e reuse, it must e instlle in the iretion of originl rottion. Instlling impeller with vnes reverse from their previous set will result in vne rekge shortly fter unit is returne to servie. 3. Instll new impeller n lign with rive key. 4. Instll neoprene wsher. 5. Lurite I.D. of wter pump over with 2-4-C w/teflon. 6. Instll over on rive shft n while pushing own on over, rotte rive shft CLOCK- WISE n instll over over impeller. -Neoprene Wsher -Drive Key -Impeller -Neoprene Wsher e -Cover 7. Apply Lotite 271 to thres of olts. Seure over with olts n torque to 50 l. in. (5.6 N m) per following numere torque sequene e C With Teflon ( A12) 7 Lotite 271 ( ) Pge R1 MAY 1998

31 Propeller Shft n Bering Crrier Instlltion GEAR HOUSING 1. Instll REVERSE ger into ering rrier. 2. If not previously lurite, pply 2-4-Cw/Teflon to o-ring. 3. Apply 2-4-C w/teflon to ering rrier thres n pilot imeter. 4. Slie ering rrier onto propeller shft n instll entire ssemly into ger housing. 5. Torque ering rrier to 85 l. ft. (115.2 N m) using Bering Crrier Tool ( ). LEFT HAND THREAD C With Teflon ( A12) -Bering Crrier Thres -Propeller Shft -Pilot Dimeter Aluminum Anoe n Wter Inlet Instlltion Seure noe n wter inlet with srews Anoe -Wter Inlet -Srews R1 MAY 1998 Pge 6-31

32 Propeller Instlltion WARNING If ger housing is NOT remove from rive shft housing, BEFORE ttempting to remove or instll the propeller, remove (n isolte) sprk plug les from sprk plugs to prevent engine from strting ientlly. 1. Apply Quiksilver Anti-Corrosion Grese to propeller shft. 2. Instll inner thrust hu. 3. Slie propeller onto shft. 4. Instll outer thrust hu. 5. Thre propeller nut onto shft Inner Thrust Hu -Propeller -Outer Thrust Hu -Propeller Nut 6. Ple lok of woo etween propeller n nti-ventiltion plte to prevent propeller from turning n to protet hns. Torque nut to 70 l. in. (7.9 N m). -Outer Thrust Hu -Nut Pge R1 MAY 1998

33 Filling Ger Housing with Lurint GEAR HOUSING NOTE: Ger housing lurint pity 6.8 oz. (200 ml). IMPORTANT: DO NOT use utomotive grese in the ger housing. Use only Quiksilver Ger Lurint ( A24) 1. Remove ny gsket mteril from FILL n VENT srews n housing. 2. Instll new gskets on FILL n VENT srews. IMPORTANT: Never pply lurint to ger housing without first removing VENT srew or ger housing nnot e fille euse of trppe ir. Fill ger housing ONLY when housing is in vertil position. 3. Slowly fill housing through FILL hole until lurint flows out of VENT hole n no ir ules re present. 4. Reinstll VENT srew. 5. Remove grese tue from FILL hole n quikly instll FILL srew. Instlltion -Vent Srew -Fill Srew WARNING To prevent ientl engine strting, remove (n isolte) sprk plug les from sprk plugs. BEFORE instlling ger housing. 1. Remove (n isolte) sprk plugs les from sprk plugs. 2. Ple shift linkge on engine in FORWARD ger position. 3. Tilt engine to full up position. 4. Ple ger housing in NEUTRAL. Propeller will rotte freely in either iretion when ger housing is in NEUTRAL R1 MAY 1998 Pge 6-33

34 5. Position shift shft () s shown when mesuring istne in Step Distne () etween top of wter pump se n enter of hole () must e s speifie elow. Turn shift shft lokwise to erese istne () or ounter lokwise to inrese istne () Drive Shft Length Short Long Extr Long Distne 16-1/2 in. (419mm) 22 in. (559mm) 27-1/2 in. (698mm) 7. Ple ger housing in FORWARD ger. Ger housing will rthet when propeller shft is turne lokwise. 8. Apply 1/4 in. (6.4mm) imeter e of RTV Seler on wter pump se. -RTV Seler Pge R1 MAY 1998

35 9. Instll ger housing s follows:. Position ger housing so tht rive shft n shift shft exten into rive shft housing.. Move ger housing towr rive shft housing while keeping mting surfes prllel.. Guie shift shft through hole in mi-setion.. Guie wter tue into wter tue guie. e. Rotte propeller ounterlokwise while pushing upwr on ger housing to lign rive shft splines with rnkshft splines. f. Guie en of shift shft into shift oupling yoke uner owl Shift Shft Hole 10. Seure etent spring to lok with 2 olts. Spring my hve slotte holes. Instll spring so tht it is rise UP n t en of slot trvel. Torque olts to 25 l. in. (2.8 N m). 11. Seure en of shift shft to yoke of horizontl shift shft with oupler. Rotte oupler until it loks in ple. e f 2-4-C With Teflon ( A12) -Shift Shft -Yoke -Coupler -Apply 2-4-C w/teflon e -Detent Spring f -Bolts [Torque to 25 l. in. (2.8 N m)] R1 MAY 1998 Pge 6-35

36 12. Apply Lotite 271 to 3 olts n torque to 15.0 l. ft. (20.3 N m) Lotite 271 ( ) -Bolts [Torque to 15.0 l. ft. (20.3 N m)] 13. Chek shift opertion s follows:. Ple shift lever in FORWARD. Ger housing shoul rthet when propeller shft is turne lokwise n resistne shoul e felt when propeller is turne ounterlokwise.. Ple shift lever in NEUTRAL. Resistne shoul NOT e felt when propeller shft is rotte in either iretion.. Ple shift lever in REVERSE. Resistne shoul e felt when propeller shft is rotte in either iretion.. If shift opertion is not s esrie, remove ger housing n rehek istne mesurement in Step Ple shift lever in NEUTRAL. 15. Instll reverse lok tutor loosely on shift shft. 16. Position reverse lok tutor so tht it just ontts reverse lok hook; seure in this position. Torque tutor srew to 45 l. in. (5.1 N m). The outor will now ONLY TILT UP IN FORWARD GEAR. If the opertor wishes the outor to tilt up in FORWARD n NEUTRAL, ple shift lever in REVERSE. Instll reverse lok tutor loosely on shift shft. Position tutor so tht 0.25 in. (6.4mm) lerne exists etween reverse lok hook n tutor. Seure tutor in this position. Torque tutor srew to 45 l. in. (5.1 N m) Reverse Lok Atutor -Srew n Loknut [Torque to 45 l. in. (5.1 N m)] -Reverse Lok Hook Pge R1 MAY 1998

LOWER UNIT 5 A 791-H GEAR HOUSING

LOWER UNIT 5 A 791-H GEAR HOUSING Tle of Contents Pge Notes................................... 5A-1 Drive Shft n Wter Pump Components... 5A-2 Propeller Shft Components............... 5A-6 Speil Tools............................