6b Mercury

LEFT HAND NON-RATCHETING
LOWER UNIT
Section 6B – Left Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-29
(Counter Rotation) . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . 6B-31
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Reassembly and Installation of
Gear Housing Counter Rotation Gear Housing . . . . . . . . . . . 6B-32
(Drive Shaft)(Counter Rotation) . . . . . . . . . . . 6B-6 Drive Shaft Needle Bearing . . . . . . . . . . . . 6B-32
Gear Housing Bearing Carrier, Forward Gear
(Prop Shaft)(Counter Rotation) . . . . . . . . . . . . 6B-8 and Bearing Adaptor . . . . . . . . . . . . . . . . . . 6B-33
Gear Housing Reverse Gear Bearing Adaptor
(Prop Shaft)(Counter Rotation) . . . . . . . . . . . . 6B-10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-36
General Service Recommendations . . . . . . . 6B-12 Drive Shaft and Pinion Gear . . . . . . . . . . . 6B-38
Removal, Disassembly, Cleaning Pinion Gear Depth . . . . . . . . . . . . . . . . . . . . 6B-40
and Inspection of Counter Rotation (Left Hand) Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-42
Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-43
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15 Propeller Shaft/Forward Gear
Bearing Carrier and Propeller Shaft Removal . . . Bearing Adapter/Bearing Carrier . . . . . . . 6B-46
6B-18 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-53
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Gear Lubricant Filling Instructions . . . . . . 6B-56
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-22 Installing Gear Housing to Drive Shaft
Clutch Actuator Rod . . . . . . . . . . . . . . . . . . 6B-25 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-56 6
Forward Gear and Bearing Adapter . . . . . 6B-25 Propeller Installation . . . . . . . . . . . . . . . . . . 6B-58
Pinion Gear and Driveshaft . . . . . . . . . . . . 6B-27 B
Gear Housing Specifications (Counter Rotation)

Ratio Pinion Depth Forward Gear Reverse Gear
Backlash Backlash
1.87:1 0.025 in. (0.635 mm) 0.018 in. to 0.027 in. 0.030 in. to 0.050 in.
With Tool 91-12349A2 (0.460 mm to 0.686 (0.762 mm to 1.27 mm)
using Disc #2 and mm) Pointer on line
Flat #7 mark #1
2.0:1 0.025 in. (0.635 mm) 0.015 in. to 0.022 in. 0.030 in. to 0.050 in.
With Tool 91-12349A2 (0.38 mm to 0.56 mm) (0.762 mm to 1.27 mm)
using Disc #2 and Pointer on line mark
Flat #7 #2
Gearcase Lubricant Capacity
All Ratios 22.5 fl. oz. (665.4 ml)
90-855347R02 NOVEMBER 2002 Page 6B-1

Special Tools
1. Shift Shaft Bushing Tool 91-31107T
2. Gear Housing Cover Nut Tool 91-61069
3. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716
4. Slide Hammer Puller 91-34569A1
5. Bearing Removal and Installation Kit 91-31229A5. This kit contains the following
tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plate 91-29310;
Mandrel 91-38628; and Driver Rod 91-37323.
6. Pilot 91-36571
7. Puller Rod 91-31229 and Nut 91-24156
Page 6B-2 90-855347R02 NOVEMBER 2002

8. Puller Plate 91-29310
9. Mandrel 91-38628
10. Driver Rod 91-37323
11. Universal Puller Plate 91-37241
12. Drive Shaft Holding Tool 91-34377A1 or 91-90094
13. Oil Seal Driver 91-31108
14. Forward Gear Bearing Tool 91-86943
15. Pinion Gear Locating Tool 91-12349A2 or 91-74776
16. Backlash Indicator Rod 91-78473
17. Dial Indicator 91-58222A1
90-855347R02 NOVEMBER 2002 Page 6B-3

18. Bearing Retainer Tool 91-43506
19. Mandrel 91-92788
20. Mandrel 91-15755
21. Dial Indicator Holder 91-89897
22. Bearing Preload Tool 91-14311A1
7
6
5
4
3
2
1 - Adaptor (N.S.S.)
2 - Bearing (N.S.S.)
3 - Washer (N.S.S.)
4 - Spring (24-14111)
5 - Bolt (10-12580)
6 - Nut (11-13953)
7 - Set Screw (10-12575)
8 - Sleeve (23-13946)
23. Propeller Shaft 44-93003 and Load Washer 12-37429
24. Forward Gear Installation Tool 91-815850
Page 6B-4 90-855347R02 NOVEMBER 2002

25. Reverse Gear Installation Kit 91-18605A1 includes Pilot 91-18603; Retainer
91-18604; Shaft 91-18605 and Screw 10-18602
d a
a - Pilot 91-18603
b - Shaft 91-18605
c - Retainer 91-18604
d - Screw 10-18602
90-855347R02 NOVEMBER 2002 Page 6B-5

Gear Housing (Drive Shaft)(Counter Rotation)

95
49
44
4.75 IN./120.65 MM 41
45
46
TORPEDO DIA. 48
95
47
95
29
39
19 28
40
27
95
42 95
16
43
95
37
25
26
38 24
95
23
36
22
30
7
31
116 95 95
35
34
7 33 8 21
32 2
5 20
95 10
7
11 7
50 6
1918
10 4
12 33
3
95
9
13
14
1
15
7 Loctite 271 Thread Locker
7
19 Perfect Seal 19
33 Loctite 680 Retaining Compound 17
95 2-4-C With Teflon
116 RTV 587 Silicone Sealer
Page 6B-6 90-855347R02 NOVEMBER 2002

Gear Housing (Drive Shaft)(Counter Rotation)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 GEAR HOUSING (BLACK)(BASIC)
2 1 CONNECTOR ASSEMBLY
3 2 DOWEL PIN
4 1 STUD (3-11/16 IN.)
5 2 STUD (2-1/16 IN.)
6 1 STUD (3-3/8 IN.)
7 2 STUD (3-1/8 IN.)
8 1 FILLER BLOCK
9 1 ROLLER BEARING
10 2 ANODE
11 1 SCREW
12 1 NUT 60 7
1 PINION GEAR (1.87:1 - 15 TEETH)(150)(Part of 43-828701A1)
13 1 PINION GEAR (2:1 - 14 TEETH)-(135)(Also part of 43-828703A1)
14 1 WASHER
15 1 NUT 75 101
16 AR SHIM SET
17 1 SCREW–drain (MAGNETIC) 60 7
18 1 SCREW–grease filler 60 7
19 2 WASHER
20 1 STA-STRAP
21 1 SHIFT SHAFT
22 1 O-RING
23 1 BUSHING ASSEMBLY 50 5.5
24 1 OIL SEAL
25 1 WASHER–rubber
26 1 DRIVE SHAFT
27 1 ROLLER BEARING
28 1 CUP
29 1 RETAINER 100 11.5
30 1 WATER PUMP BASE
31 1 RETAINER
32 1 GASKET
33 1 O-RING
34 1 OIL SEAL
35 1 OIL SEAL
36 1 GASKET–lower
37 1 GASKET–upper
38 1 FACE PLATE
39 1 WATER PUMP BODY ASSEMBLY
40 1 INSERT
41 1 SEAL–rubber
42 1 lMPELLER
43 1 KEY
44 1 SCREW (#14-8 x 2-1/4 IN.) 35 4
45 2 WASHER
46 2 NUT 50 5.5
47 1 WASHER
48 1 NUT 50 5.5
49 1 SLEEVE
50 1 DECAL-Counter Rotation
90-855347R02 NOVEMBER 2002 Page 6B-7

Gear Housing (Prop Shaft)(Counter Rotation)

85
4.75 IN./120.65 MM
TORPEDO DIA.
86
95
87
84 88
52
82
51
53
82 58
54
66
60 65
95
55 82
64 56
63
57 82 94
87 69
82
67
61 59 68
62 70
95
71
82 76
72
73 82
82 7
74 77
75 95 78
74 79
80 82
73 95
72
81
83
95
7 Loctite 271 Thread Locker 94 Anti-Corrosion Grease

82 Premium Gear Lubricant 95 2-4-C With Teflon
Page 6B-8 90-855347R02 NOVEMBER 2002


TORQUE
REF.
REF
51 1 CAM FOLLOWER
52 1 SHIFT CAM
53 1 ROD
54 AR SHIM SET
55 1 BEARING ADAPTOR ASSEMBLY
56 1 ROLLER BEARING
57 1 THRUST WASHER
58 1 THRUST BEARING
1 REVERSE GEAR (1.87:1 – 15/28)(150)
59
1 REVERSE GEAR (2:1 – 14/28)-(135)
60 1 ROLLER BEARING
61 1 SPRING
62 1 SLIDING CLUTCH
63 1 CROSS PIN
64 1 DETENT PIN
65 1 PROPELLER SHAFT
1 FORWARD GEAR (1.87:1 – 15/28)(150)
66
1 FORWARD GEAR (2:1 – 14/28)-(135)
AR SPACER SHIM .206 IN.
67 AR SPACER SHIM .218 IN.
90-855347R02 NOVEMBER 2002 Page 6B-9


85
4.75 IN./120.65 MM
TORPEDO DIA.
86
95
87
84 88
52
82
51
53
82 58
54
66
60 65
95
55 82
64 56
63
57 82 94
87 69
82
67
61 59 68
62 70
95
71
82 76
72
73 82
82 7
74 77
75 95 78
74 79
80 82
73 95
72
81
83
95
7 Loctite 271 Thread Locker 94 Anti-Corrosion Grease

82 Premium Gear Lubricant 95 2-4-C With Teflon
Page 6B-10 90-855347R02 NOVEMBER 2002


TORQUE
REF.
REF
68 1 ROLLER BEARING
69 1 THRUST WASHER
70 1 BEARING ADAPTOR ASSEMBLY
71 1 ROLLER BEARING
72 2 THRUST WASHER
73 2 THRUST BEARING
74 2 THRUST RACE
75 2 KEEPER
76 1 O RING
77 1 BEARING CARRIER ASSEMBLY
78 1 ROLLER BEARING
79 1 OIL SEAL (INSIDE)
80 1 OIL SEAL (OUTSIDE)
81 1 TAB WASHER
82 1 KEY
83 1 COVER 210 285
84 1 TRIM TAB
85 1 SCREW (1-3/4 IN.) 25 34
86 1 SCREW (3/8-16 x 1) 30 41
87 2 WASHER
88 2 NUT 50 68
90-855347R02 NOVEMBER 2002 Page 6B-11

General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part, there-
fore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more compo-
nents.
Service procedure order in this section is a normal disassembly-reassembly sequence.
It is suggested that the sequence be followed without deviation to assure proper repairs.
When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to reassembly and installation of that compo-
nent in the reassembly part of this section. Use the Table of Contents to find correct page
number.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in air line.
BEARINGS
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing
so that it passes through the bearing. DO NOT spin bearing with compressed air, as this
may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with
Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work the inner
bearing race in and out, while holding outer race, to check for side wear. When inspecting
tapered bearings, determine condition of rollers and inner bearing race by inspecting
bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discol-
oration from over-heating. Always replace tapered bearing and race as a set.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that
the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded
particles, uneven wear and/or discoloration from overheating. The shaft and bearing must
be replaced, if the conditions described are found.
SHIMS
Keep a record of all shim amounts and location during disassembly to aid in reassembly.
Be sure to follow shimming instructions during reassembly, as gears must be installed to
correct depth and have the correct amount of backlash to avoid noisy operation and pre-
mature gear failure.
SEALS
As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard
to appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter
of all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean
and dry. To ease installation, apply 2-4-C with Teflon on all O-rings. To prevent wear, apply
2-4-C with Teflon on l.D. of oil seals. To prevent corrosion damage after reassembly, apply
2-4-C with Teflon to external surfaces of bearing carrier and cover nut threads prior to in-
stallation.
Page 6B-12 90-855347R02 NOVEMBER 2002

Removal, Disassembly, Cleaning and Inspection of Counter

Rotation (Left Hand) Gear Housing
REMOVAL
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from
engine before removing gear housing from drive shaft housing.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.
CAUTION
Gear housing MUST BE in NEUTRAL position and shift shaft MUST BE removed
from gear housing BEFORE propeller shaft can be removed from gear housing.
2. Shift engine into NEUTRAL position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller
locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propeller
shaft.
c
a
f
b
d 51916
51912
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut
5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position.
Remove plastic cap at rear edge of driveshaft housing. Remove bolt that secures trim
tab and remove tab from gear housing.
6. Once trim tab is removed, remove bolt from inside of trim tab cavity.
90-855347R02 NOVEMBER 2002 Page 6B-13

7. Remove 2 locknuts from bottom middle of anti-cavitation plate.
a
b
51866
a - Bolt (Secures Trim Tab)
b - Bolt (Inside Trim Tab Cavity)
c - Locknuts and Washers
8. Remove locknut from the front gear housing mounting stud.

9. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before the
opposite side is loosened sufficiently, or driveshaft housing could be damaged.)
b
a
51873
a - Front Mounting Locknut
b - Side Mounting Locknut (One Each Side)
10. Pull gear housing away from driveshaft housing as far as the loosened nuts (in Step
9) will allow, then remove loosened nuts. (DO NOT allow gear housing to fall, as it now
is free.)
11. Pull gear housing from driveshaft housing.
Page 6B-14 90-855347R02 NOVEMBER 2002

DRAINING AND INSPECTING GEAR HOUSING LUBRICANT

1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical
position, as shown.
NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later
models.
2. Position a clean drain pan under gear housing and remove Fill and Vent screws from
gear housing.
3. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal
particles (resembling powder) indicates normal wear. Presence of larger particles (or
a large quantity of fine particles) indicates need for gear housing disassembly, and
component inspection.
4. Note the color of gear lubricant. White or cream color indicates presence of water in
lubricant. Check drain pan for water separation from lubricant. Presence of water in
gear lubricant indicates the need for disassembly, and inspection of oil seals, seal sur-
faces, O-rings and gear housing components.
IMPORTANT: Gear lubricant drained from a recently run gearcase will be a light
chocolate brown in color due to agitation/aeration. Oil which is stabilized will be
a clear yellow brown in color.
a
51871
a - Fill Screw
b - Vent Screw
Water Pump
CLEANING AND INSPECTION
1. Clean all water pump parts with solvent and dry with compressed air.
2. Inspect water pump cover and base for cracks and distortion (from overheating).
3. Inspect face plate and water pump insert for grooves and/or rough surfaces.
IMPORTANT: When completing gear housing repairs, that require removal of water
pump impeller, it is recommended that the impeller be replaced. If it is necessary
to re-use impeller, DO NOT install in reverse to original rotation, or premature im-
peller failure will occur.
4. Inspect impeller side seal surfaces and ends of impeller blades for cracks, tears and
wear. Replace impeller if any of these conditions are found.
5. Inspect impeller bonding to impeller hub.
6. Inspect impeller for glazed or melted appearance (caused by operation without suffi-
cient water supply). Replace impeller if any of these conditions exist.
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
90-855347R02 NOVEMBER 2002 Page 6B-15

REMOVAL AND DISASSEMBLY

1. Slide rubber centrifugal slinger up and off driveshaft.
2. Remove water tube guide and seal from water pump cover. (Retain guide for reas-
sembly and discard seal.)
3. Remove (and retain) 3 nuts, one bolt and all washers which secure water pump cover
to gear housing.
4. Using 2 pry bars, lift water pump cover up and off driveshaft.
51874
c
51874
a - Water Tube Guide
b - Water Tube Seal
c - Nuts, Bolt and Washers to be Removed
5. Inspect water pump cover and insert as outlined in Cleaning and Inspection, previous.
6. If inspection of water pump insert determines that replacement is required, follow Step
“a” or “b” (immediately following) to remove insert from water pump cover.
NOTE: Try Step “a” first. If insert cannot be removed with Step “a,” use Step “b.”
a. Drive water pump insert out of water pump cover with a punch and hammer.
b. Drill two 3/16 in. (4.8 mm) diameter holes through the top of water pump cover (but
not through insert). Drive insert out of cover with a punch and hammer.
51874 51873
a - Drill Two Holes at These Locations
Page 6B-16 90-855347R02 NOVEMBER 2002

7. Remove impeller from driveshaft. (It may be necessary to use a punch and hammer
to drive impeller upward on driveshaft. In extreme cases, it may be necessary to split
hub of impeller with a hammer and chisel.)
8. Once impeller is removed, remove impeller drive key from driveshaft.
9. Remove water pump face plate and both gaskets (one above and below face plate)
from water pump base.
10. Using 2 pry bars, positioned and padded as shown, lift water pump base up and off
driveshaft.
a
51874
a - Pads
11. Remove (and discard) O-ring from O-ring groove on water pump base.
12. Using a screwdriver, pry oil seals out of water pump base from gear housing side of
base.
90-855347R02 NOVEMBER 2002 Page 6B-17

Bearing Carrier and Propeller Shaft Removal

CAUTION
Gear housing MUST BE in neutral position, and shift shaft MUST BE removed
from gear housing before propeller shaft can be removed from gear housing.
1. Place gear housing in a suitable holding fixture (or vise), with propeller shaft in a
horizontal position.
2. Use Shift Shaft Bushing Tool to unthread shift shaft bushing. (DO NOT remove bush-
ing from shift shaft at this time.)
3. Bend retainer nut lock tab out of retainer nut recess.
b
d c
51882 51865
a - Shift Shaft Bushing Tool (91-31107)
b - Shift Shaft Bushing
c - Punch
d - Tab of Tab Washer
4. Remove gear housing retainer nut with Retainer Nut Tool.

5. After retainer nut has been removed, remove lock tab washer from gear housing.
a b
51911 51885
a - Retainer Nut Tool (91-61069)
b - Retainer Nut
c - Tab Washer
Page 6B-18 90-855347R02 NOVEMBER 2002

CAUTION
Once bearing carrier is removed from gear housing, extreme care MUST BE taken
not to apply any side force on propeller shaft. Side force on propeller shaft may
break the neck of the clutch actuator rod.
6. Use long Puller Jaws and Puller Bolt to remove bearing carrier. (Use propeller thrust
hub to maintain outward pressure on puller jaws.)
NOTE: When bearing carrier is removed from gear housing, the bearing carrier alignment
key will come out with it.
a
b
c 51867
a - Long Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
c - Thrust Hub
SHIFT SHAFT REMOVAL

IMPORTANT: Prior to removal of shift shaft from gear housing, recheck that gear
housing is in neutral position.
7. With gear housing in neutral, pull shift shaft out of gear housing. If necessary, use a
pliers to pull shift shaft out of gear housing. If pliers are used to pull shift shaft out, wrap
a strip of soft metal (aluminum) around splines before clamping pliers. DO NOT turn
shaft (clockwise OR counterclockwise) while pulling shaft out.
51867
a - Shift Shaft Bushing
b - Shift Shaft
90-855347R02 NOVEMBER 2002 Page 6B-19

CAUTION
Propeller shaft, cam follower and shift cam, in most cases, will come out of gear
housing by simply pulling outward on propeller shaft. DO NOT FORCE shaft side-
ways or ATTEMPT TO PULL with a slide hammer or any mechanical puller.
8. Remove propeller shaft, cam follower and shift cam by pulling shaft straight out of gear
housing. (DO NOT JERK propeller shaft.)
NOTE: Sliding clutch, forward gear assembly, bearing adaptor, thrust washer and thrust
bearings will be removed from gearcase with propeller shaft.
51877
9. If propeller shaft will not come out, proceed with Step “a” or “b,” following:
a. Push propeller shaft back into place against the reverse gear. Visually inspect
location of shift cam by looking down shift shaft hole (illuminated with a flashlight).
If splined hole in shift cam is visible, reinstall shift shaft and rotate shift shaft to
neutral position. Remove shift shaft, then remove propeller shaft as instructed
in Step 8, immediately preceding.
b. Push propeller shaft back into place against reverse gear. Slide bearing carrier
back into gear housing (to support propeller shaft). Place gear housing on its left
side (viewed from rear) and strike upper leading end of gear housing with a rubber
mallet. This will dislodge the shift cam from cam follower into a clearance pocket
in left side of gear housing. Remove bearing carrier and pull propeller shaft out
of gear housing.
NOTE: If Step 9-b was used to remove propeller shaft, the shift cam can be retrieved after
removal of reverse gear.
SHIFT SHAFT CLEANING AND INSPECTION
1. Clean shift shaft and bushing with solvent and dry with compressed air.
2. Check shift shaft splines on both ends for wear and/or corrosion damage.
3. Inspect shift shaft for grooves at shift shaft bushing seal surface.
4. Inspect shift shaft bushing for corrosion damage.
5. Inspect shift shaft bushing oil seal for wear and/or cuts.
SHIFT SHAFT DISASSEMBLY
1. Remove (and discard) shift shaft bushing oil seal by prying it out or driving it out with
a punch and hammer.
Page 6B-20 90-855347R02 NOVEMBER 2002

Bearing Carrier
CLEANING/INSPECTION
IMPORTANT: It is recommended that all seals and O-rings be replaced (as a normal
repair procedure) to assure effective repair.
CAUTION
DO NOT spin bearings dry with compressed air, as this could cause bearing to
score.
1. Clean bearing carrier with solvent and dry with compressed air.
2. Bearing carrier propeller shaft needle bearing condition is determined by propeller
shaft bearing surface condition. (See Propeller Shaft Inspection.)
DISASSEMBLY
1. Remove thrust bearing and thrust washer from bearing carrier.
2. If thrust bearing, thrust washer or thrust bearing surface on propeller shaft shows
signs of rust, pitting or discoloration (blueing) from lack of lubricant, components
should be discarded.
3. Remove bearing carrier oil seals.
a d
e
c b
f
g
51878
51886
a - Thrust Bearing
b - Thrust Washer
c - Bearing Carrier
d - Pry Bar
e - Oil Seals
f - Bearing Carrier
g - Bearing Carrier Needle Bearing
NOTE: Do not remove bearing carrier needle bearing unless replacement is needed.
90-855347R02 NOVEMBER 2002 Page 6B-21

4. Use Driver Rod and Mandrel (from Bearing Removal and Installation Tool) to press
bearings out of bearing carrier.
51885
a - Needle Bearing
b - Driver Rod (91-37323)
c - Mandrel (91-38628T)
Propeller Shaft
INSPECTION
1. Clean propeller shaft assembly with solvent and dry with compressed air.
2. Inspect bearing carrier oil seal surfaces for grooves. Run fingernail across seal sur-
face to check for groove. Replace shaft if groove is found.
3. Visually check bearing surfaces of propeller shaft for pitting, grooves, scoring, uneven
wear or discoloration from overheating. Replace shaft and corresponding needle
bearing if any of these conditions are found. (Bearing carrier needle bearing contacts
propeller shaft just in front of oil seal surface. Reverse gear bearing contacts propeller
shaft in front of sliding clutch splines.)
4. Inspect propeller shaft splines for wear and/or corrosion damage.
5. Check propeller shaft for straightness. Use either method, following:
Balance Wheels
Place propeller shaft on balance wheels, as shown. Rotate propeller shaft and observe
propeller end of shaft for wobble. Replace shaft if any wobble is observed.
b
a
51877
a - Balance Wheels c - Watch for Wobble
b - Bearing Surfaces
Page 6B-22 90-855347R02 NOVEMBER 2002

“Vee” Blocks and Dial Indicator

Position propeller shaft roller bearing surfaces on vee blocks. Mount a dial indicator at
front edge of propeller splines. Rotate propeller shaft. Dial indicator movement of more
than 0.006 in. (0.152 mm) (or noticeable wobble) is reason for replacement.
DISASSEMBLY
1. Remove shift cam from cam follower.
2. Insert a thin blade screwdriver or awl under first coil of cross pin retainer spring and
rotate propeller shaft to unwind spring from sliding clutch. DO NOT overstretch spring.
a
51875
a - Cross Pin Retainer Spring
CAUTION
Detent pin is free and can fall out of sliding clutch. Care MUST BE taken not to lose
pin.
3. Detent pin is free and can be removed from sliding clutch at this time.
4. Push cross pin out of sliding clutch and propeller shaft with a punch.
c
d
b
e
51879
51875
a - Detent Pin
b - Cross Pin
c - Sliding Clutch
d - Cross Pin
e - Punch
90-855347R02 NOVEMBER 2002 Page 6B-23

5. Pull sliding clutch off propeller shaft.

6. Inspect sliding clutch. Check reverse gear clutch jaws and forward gear clutch jaws.
Rounded jaws indicate one or more of the following:
a. Improper shift cable adjustment.
b. Improper shift habits of operators (shift from neutral to reverse gear or forward
gear too slowly).
c. Engine idle speed too high (while shifting).
b
a
51875
a - Sliding Clutch
b - Reverse Gear Clutch Jaws
c - Forward Gear Clutch Jaws
7. Pull cam follower and clutch actuator rod out of propeller shaft. DO NOT force cam
follower up or down or side to side when pulling from propeller shaft.
8. Once cam follower and clutch actuator rod are removed from propeller shaft, lift rod
out of cam follower.
9. Check condition of cam follower. If it shows wear (pitting, scoring or rough surface),
replace cam follower and shift cam.
10. Remove forward gear and bearing adaptor assembly.
11. Remove 2 thrust races and 2 keepers from prop shaft.
c e
f
d
a b 55097
51884
a - Cam Follower
b - Clutch Actuator Rod
c - Forward Gear
d - Bearing Adaptor Assembly
e - Thrust Races (2)
f - Keepers (hidden) (2)
Page 6B-24 90-855347R02 NOVEMBER 2002

Clutch Actuator Rod

1. Clean clutch actuator rod in solvent and dry with compressed air.
2. Inspect actuator components for wear or damage. Replace components as required.
Forward Gear and Bearing Adapter
DISASSEMBLY/CLEANING/INSPECTION
1. Remove forward gear from bearing adapter.
2. Inspect forward gear clutch teeth for signs of wear. If clutch teeth are worn, sliding
clutch should be replaced also.
3. Inspect forward gear teeth for full tooth contact, chips, pits and signs of rust. If forward
gear teeth are damaged, pinion gear must be inspected and replaced if necessary.
4. Inspect forward gear hub for signs of pitting, rust, scoring or discoloration due to lack
of lubricant.
5. Remove the thrust bearing and spacer shim. Inspect thrust bearing for pits, rust, or
discoloration due to lack of lubricant.
b a
c
g
51878
a - Forward Gear
b - Forward Gear Clutch Teeth
c - Forward Gear Teeth
d - Forward Gear Hub
e - Thrust Bearing
f - Thrust Washer
g - Spacer Shim
90-855347R02 NOVEMBER 2002 Page 6B-25

6. Remove thrust washer and O-ring. The thrust washer acts as a bearing surface for
the thrust bearing and it should be inspected for pits, rust, scoring or discoloration due
to lack of lubricant. O-ring should be inspected for cuts or abrasions and replaced if
necessary.
7. Remove thrust bearing and thrust washer from bearing adaptor. Thrust roller bearing
should be inspected for pitting, rust or signs of discoloration due to lack of lubricant.
If thrust roller bearing must be replaced, the bearing surfaces on the thrust washer and
propeller shaft where the thrust roller bearing rides should also be inspected for signs of
wear.
b e
55089
55090
a - Thrust Washer
b - O-Ring (hidden)
c - Thrust Bearing
d - Thrust Washer
e - Bearing Adaptor
8. The forward gear bearing should be carefully inspected for smoothness of movement,
pits, rust, or signs of discoloration due to lack of lubricant. If the bearing must be
replaced, it is recommended that a hammer and cape chisel be used to break the
bearing loose from the bearing adapter. Be careful not to damage bearing adapter
when removing roller bearing.
a
b
55091
a - Forward Gear Bearing
b - Bearing Adaptor
Page 6B-26 90-855347R02 NOVEMBER 2002

Pinion Gear and Driveshaft

REMOVAL
1. Remove bearing retainer using Bearing Retainer Tool.
a
51865
a - Bearing Retainer
b - Bearing Retainer Tool (91-43506)
2. Place Driveshaft Holding Tool (91-34377A1) over driveshaft splines.

3. Use a socket and flex handle to hold pinion nut. (Pad area of gear housing, where flex
handle will make contact, to prevent damage to gear housing.)
4. Use a socket and flex handle on Driveshaft Holding Tool to loosen pinion nut. Remove
pinion nut and Driveshaft Holding Tool.
5. Remove gear housing from vise and reposition it as shown. Be sure to use soft jaw
vise covers and clamp as close as possible to water pump studs.
6. Place a block of wood on gear housing mating surface. Use a mallet and carefully tap
gear housing away from driveshaft.
CAUTION
DO NOT strike gear housing hard with the mallet or allow gear housing to fall.
b a
51878
a - Wooden Block
b - Soft Jaw Vise Covers
90-855347R02 NOVEMBER 2002 Page 6B-27

7. Reach into gear housing and remove pinion gear.

8. After driveshaft is removed from gearcase, remove and retain shims that were located
under upper tapered driveshaft bearing.
9. If inspection determines that replacement of driveshaft tapered bearing is required,
remove bearing from driveshaft as follows:
a. Position driveshaft in a vise; DO NOT tighten vise jaws against shaft.
b. Strike shaft with a lead hammer; take care not to drop shaft.
51866
10. Remove 18 loose needles from outer race of driveshaft needle bearing.
11. If inspection of driveshaft needle bearing surface determines that replacement of
needle bearing is required, the 18 loose needle bearings previously removed must
be reinstalled in bearing race to provide surface for mandrel to drive against.
NOTE: Reverse gear must be removed first before removing driveshaft needle bearing.
IMPORTANT: Discard driveshaft needle bearing after removal. (Bearing cannot be
reused.)
51869
a - Mandrel (91-37263)
b - Pilot* (91-36571)
c - Driver Rod* (91-37323)
*From Bearing Removal and Installation Kit (91-31229A5)
Page 6B-28 90-855347R02 NOVEMBER 2002


1. Clean driveshaft, tapered bearing and race, and pinion gear with solvent. Dry with
compressed air. DO NOT allow driveshaft bearing to spin while drying.
2. Inspect pinion gear for pitting, grooves, scoring, uneven wear and/or discoloration
from overheating. Replace pinion gear, if any of the above conditions are found.
3. Inspect driveshaft needle bearing surface (area just above pinion gear splines) for
pitting, grooves, scoring, uneven wear and/or discoloration from overheating. Replace
driveshaft and driveshaft needle bearing, if any of the preceding conditions are found.
4. Inspect drive shaft to crankshaft splines for wear. Replace the drive shaft if wear is
excessive.
5. Inspect tapered bearing race for pitting, grooves, scoring, uneven wear and/or dis-
coloration from overheating. Replace tapered bearing and race as a set, if any of the
preceding conditions are found.
6. Inspect driveshaft for grooves where water pump base oil seals contact shaft. Replace
driveshaft if grooves are found.
Reverse Gear
REMOVAL AND DISASSEMBLY
NOTE: Reverse gear can be removed from gear housing only after driveshaft and pinion
gear have been removed.
NOTE: Cautiously applying heat to both sides of gearcase where reverse gear assembly
is located will aid in removal of bearing cup adapter.
1. Remove reverse gear by hand.
50884
a - Reverse Gear
IMPORTANT: DO NOT remove needle bearing from reverse gear unless replace-
ment of bearing is required. Bearing cannot be reused after it has been removed.
90-855347R02 NOVEMBER 2002 Page 6B-29

2. Remove thrust bearing and thrust washer from reverse gear bearing cup.
3. Remove reverse gear bearing adaptor. Remove, measure and make note of the shim
thickness and discard (DO NOT reuse) the shims.
d g f
e
b i
c 50882
50780
a - Thrust Bearing
b - Thrust Washer
c - Reverse Gear Bearing Adaptor
d - Bolt (91-31229)
e - Nut (91-11-24156)
f - Guide Plate (91-816243)
g - Washer (91-34961)
h - Puller Head (from Slide Hammer Puller Kit 91-34569A1)
i - Jaws (91-816242)
CAUTION
DO NOT spin bearings dry with compressed air, This could cause bearing to score.
1. Clean reverse gear and bearing with solvent and dry with compressed air. DO NOT
spin the bearing.
2. Inspect gear teeth for pitting, grooves, scoring, uneven wear and for discoloration
(from overheating). Replace gear if any of these conditions are found.
3. Check clutch jaws on reverse gear for damage. Replace reverse gear if damage is found.
23351
a - Reverse Gear Teeth

b - Clutch Jaws
Page 6B-30 90-855347R02 NOVEMBER 2002

NOTE: The needle bearings in the reverse gear should not be removed unless damage
has been found. Inspect to ensure that all of the needles are present and in position.
Needles that have been dislodged may be snapped back into place as long as no damage
has occurred to the bearing cage.
4. Inspect the needle bearings on the inside of the reverse gear and the bearing surface
on the propeller shaft. If either the needle bearings or the bearing surface of propeller
shaft is pitted grooved, worn unevenly, discolored from overheating or has embedded
particles, replace the propeller shaft and needle bearing in the reverse gear.
a
a - Reverse Gear Needle Bearing Contact Area
5. If reverse gear needle bearing is found to be damaged, place reverse gear in a press
and use mandrel 91-36569T to press bearing out of gear.
a
50778
a - Bearing
Gear Housing
1. Clean gear housing with solvent and dry with compressed air.
2. Check gear housing carefully for impact damage.
3. Check for loose fitting bearing adaptors and needle bearings.
NOTE: If bearing adaptors have spun in gearcase, gear housing must be replaced.
4. Inspect bearing carrier cover nut retainer threads in gear housing for corrosion damage
and/or stripped threads.
90-855347R02 NOVEMBER 2002 Page 6B-31

Reassembly and Installation of Counter Rotation Gear

Housing
Drive Shaft Needle Bearing
REASSEMBLY/INSTALLATION
CAUTION
If drive shaft needle bearing failure has occurred, and original bearing race has
turned in the gear housing, gear housing must be replaced. Loose fitting needle
bearing will move out of position and cause repeated failures.
NOTE: Drive shaft needle bearing must be installed prior to installation of reverse gear.
1. Apply a thin coat of 2-4-C with Teflon to drive shaft needle bearing bore in gear housing.
2. By way of propeller shaft cavity, place needle bearing in drive shaft bore with numbered
side of bearing facing up drive shaft bore.
3. Install and seat needle bearing with the following tools: Puller Rod, Nut, Pilot, Plate,
and Mandrel. Pull bearing up into bore until it bottoms on gear housing shoulder. (DO
NOT use excessive force.)
e
g
d
a
51869
a - Mandrel* (91-92788)
b - Bearing
c - Pilot* (91-36571)
d - Plate* (91-29310)
e - Puller Rod* (91-31229)
f - Hold
g - Nut* (91-24156)
*From Bearing Removal and Installation Kit (91-31229A5)
Page 6B-32 90-855347R02 NOVEMBER 2002

Bearing Carrier, Forward Gear and Bearing Adaptor

REASSEMBLY
1. Using suitable mandrel, press forward gear bearing into bearing adaptor until bearing
is flush with lip of adaptor.
a
b
a - Suitable Mandrel
b - Forward Gear Bearing
c - Bearing Adaptor
PROPELLER SHAFT NEEDLE ROLLER BEARING AND OIL SEAL INSTALLATION

1. Using mandrel, press bearing carrier needle bearing (number side up) into bearing
carrier until mandrel shoulder contacts bearing carrier.
a
d
c
b
51881
a - Mandrel (91-15755)
b - Bearing Carrier Needle Bearing
c - Bearing Carrier
d - Shoulder
2. Apply Loctite 271 to outside diameter of oil seals.
90-855347R02 NOVEMBER 2002 Page 6B-33

3. With seal lip facing towards bearing, press inner seal using long end of mandrel into
bearing carrier until mandrel shoulder bottoms out on bearing carrier.
d
a
51881
a - Inner Seal
b - Mandrel (91-31108)
c - Bearing Carrier
d - Mandrel Shoulder
4. With seal lip facing towards mandrel, press outer seal using short end of mandrel into
bearing carrier until mandrel shoulder bottoms out on bearing carrier.
a d
51881
a - Outer Seal
b - Mandrel (91-31108)
c - Bearing Carrier
d - Mandrel Shoulder
5. Lubricate both seal lips with 2-4-C with Teflon.
Page 6B-34 90-855347R02 NOVEMBER 2002

REVERSE GEAR AND BEARING CUP ADAPTOR REASSEMBLY

1. With reverse gear teeth facing down, use mandrel to press the propeller shaft needle
bearing (numbers/letters up) into reverse gear until the short shoulder on the mandrel
bottoms on reverse gear.
NOTE: If gear housing has been replaced or inspection determines that reverse gear
bearing adapter must be replaced, assemble and install as follows:
2. Place reverse gear roller bearing (number/letters up) in press. Using suitable mandrel,
press bearing cup adapter onto reverse gear bearing.
b
e
d
c
f
a g
51883
a - Reverse Gear Teeth
b - Mandrel (91-86943)
c - Propeller Shaft Needle Bearing
d - Shoulder
e - Mandrel
f - Bearing Cup Adapter
g - Reverse Gear Roller Bearing
IMPORTANT: The appearance of the forward and reverse gear is almost identical.
There are two ways to distinguish between the reverse and forward gears. The
reverse gear has a shorter hub and it has a smaller inner diameter needle bearing
bore.
d
a b 50885
a - Reverse Gear
b - Forward Gear
c - Shorter Length Hub
d - Smaller Diameter Bearing Bore
90-855347R02 NOVEMBER 2002 Page 6B-35

Reverse Gear Bearing Adaptor Assembly

INSTALLATION
NOTE: If the reverse gear, reverse gear adaptor, large thrust bearing, or bearing race in
the gear housing were not replaced, install the same shims (or the same thickness of
shims) that were taken out when adaptor was removed. If the reverse gear, reverse gear
adaptor, large thrust bearing, bearing race, or gear housing were replaced, install 0.008
in. (0.51 mm) of shims.
NOTE: If backlash has already been checked and it has determined that it needs to be
adjusted, (see Checking Reverse Gear Backlash), adding 0.001 in. (0.025 mm) shims will
reduce the gear backlash by approximately 0.001 in. (0.025 mm). Subtracting 0.001 in.
(0.025 mm) shims will increase backlash by approximately the same amount.
Example 1 (if backlash is too high)

Backlash checks: 0.045 in. (1.14 mm)
(subtract) middle
of 0.025 in. (0.64 mm)
specification:
You get: 0.020 in. (0.51 mm)
add this quantity of shims:
Example 2 (if backlash is too low)
middle of specification: 0.025 in. (0.64 mm)
Backlash checks: 0.009 in. (0.23 mm)
(subtract) You get: 0.016 in. (0.41 mm)
subtract this quantity of shims:
1. Lubricate the bore into which the reverse gear bearing adaptor is to be installed with
Premium Gear Lubricant.
2. Place the shims into reverse bore of gear housing.
3. Position the bearing adaptor in the gear housing.
55099
a - Bearing Adaptor
b - Shims
Page 6B-36 90-855347R02 NOVEMBER 2002

4. Position reverse gear (without the thrust race or thrust bearing) into gear housing and
into the adaptor.
5. Install pilot ring over driver tool and seat pilot ring in gearcase against inner ledge.
Thread retainer into bearing carrier threads. Install screw into retainer and gently
tighten screw against driver tool while holding retainer securely. Continue to apply
pressure against driver rod until reverse gear/bearing cup adaptor just seats in gear-
case. DO NOT OVER-SEAT the adaptor as the reverse gear bearing will be damaged.
As bearing adaptor begins to seat, the effort required to turn screw will increase con-
siderably.
e b
f c
d
55100
a - Reverse Gear
b - Pilot Ring (91-18603)
c - Driver Tool (91-18605)
d - Inner Ledge
e - Retainer (91-18604)
f - Screw (10-18602)
6. After reverse bearing adaptor is seated, remove screw, retainer, driver tool, pilot ring
and reverse gear. Apply Premium Gear Lubricant to thrust bearing and install thrust
race and bearing onto bearing adaptor.
7. Reinstall reverse gear into bearing adaptor.
a
d
b f e
c
55101 g
55102
a - Thrust Bearing
b - Thrust Washer
c - Bearing Adaptor
d - Reverse Gear
e - Thrust Bearing
f - Thrust Washer (under thrust bearing)
g - Bearing Adaptor
90-855347R02 NOVEMBER 2002 Page 6B-37

Drive Shaft and Pinion Gear

1. Apply a light coat of Premium Gear Lubricant on l.D. of drive shaft tapered bearing.
2. Thread a used pinion nut onto end of drive shaft. Leave approximately 1/16 in. (2 mm)
of nut threads exposed. drive shaft threads MUST NOT extend beyond nut or thread
damage could result while pressing.
3. Place bearing over drive shaft.
4. Using an old drive shaft bearing inner race or other suitable mandrel (which applies
pressing force on center bearing race only), press bearing onto shaft until seated.
c
d
e
50064
a - Used Pinion Nut
b - Drive Shaft
c - Tapered Bearing
d - Old Bearing Inner Race
e - Universal Puller Plate
5. Position pinion gear in gear housing below drive shaft bore with teeth of pinion gear
meshed with teeth of reverse gear.
6. Insert drive shaft into drive shaft bore while holding pinion gear. Rotate drive shaft to
align and engage drive shaft splines with pinion gear splines. Continue to insert drive
shaft into gear housing until drive shaft tapered bearing is against bearing race.
7. Apply Loctite 271 to threads of pinion gear nut and install flat washer and nut on drive
shaft with flat side of nut away from pinion gear.
8. Place shims (retained from disassembly) into gear housing. If shims were lost or are
not reusable (damaged), start with approximately 0.010 in. (0.254 mm).
Page 6B-38 90-855347R02 NOVEMBER 2002

9. Install bearing race and bearing retainer.
b
a
51880
a - Shims
b - Bearing Race
c - Bearing Retainer (Word “OFF” must be visible); Torque to 100 lb. ft. (135.5 Nm)
d - Bearing Retainer Tool (91-43506)
10. Use a socket and breaker bar to hold pinion nut (pad area where flex handle will con-
tact gear housing while torquing nut).
11. Place Drive Shaft Holding Tool over crankshaft end of drive shaft. Torque pinion nut
to 75 Ib. ft. (101.5 Nm).
c
b a
d
a - Drive Shaft Holding Tool (91-34377A1)
b - Torque Wrench; Torque Nut to 75 lb. ft. (101.5 Nm)
c - Socket
d - Breaker Bar
IMPORTANT: Wipe any excess Loctite from pinion nut and pinion gear.
90-855347R02 NOVEMBER 2002 Page 6B-39

Pinion Gear Depth

DETERMINING PINION GEAR DEPTH
NOTE: Read entire procedure before attempting any change in shim thickness.
IMPORTANT: Reverse gear assembly must be installed in gear housing when
checking pinion gear depth or an inaccurate measurement will be obtained.
1. Clean gear housing bearing carrier shoulder.
2. Install Bearing Preload Tool (91-14311A1) over drive shaft in sequence shown.
NOTE: Bearing Preload Tool (91-44307A1) may also be used. Follow instructions provided
with tool for proper installation.
h
g g
b
a
a - Adaptor
b - Bearing
c - Washer
d - Spring
e - Nut; thread nut all the way onto bolt
f - Bolt
g - Set Screw
h - Sleeve; holes in sleeve must align with set screws
3. Align adaptor on drive shaft bearing pocket ledge.

4. With tool installed over drive shaft, tighten both set screws securely, making certain
to align sleeve holes to allow set screws to pass through.
Page 6B-40 90-855347R02 NOVEMBER 2002

5. Measure distance (a) and increase that distance by 1 in. (25.4 mm) by turning bottom
nut away from top nut.
1 in. (25.4 mm)
a b
c
51870
a - Distance b - Adaptor
c - Ledge
6. Turn drive shaft clockwise 2 or more turns to seat drive shaft bearings.
7. Insert Pinion Gear Locating Tool into gear housing until it bottoms out on bearing carrier
shoulder.
NOTE: Pinion Gear Locating Tool (91-12349A2) can be used. Use flat #7 and disc #2.
Follow instructions supplied with tool.
8. Determine pinion gear depth by inserting a feeler gauge through access slot in pinion
gear shimming tool.
9. Clearance between shimming tool and pinion gear should be 0.025 in. (0.64 mm).
10. If clearance is correct, leave Bearing Preload Tool on drive shaft for Determining
Forward Gear Backlash, following.
11. If clearance is not correct, add/subtract shims at location shown to raise/lower pinion
gear. When reinstalling pinion nut, apply Loctite 271 on threads of nut and retorque
pinion nut.
cc b
d
aa
cc
aa
24643
a - Pinion Gear Locating Tool (91-74776 or 91-12349A2)
b - Feeler Gauge
c - Obtain 0.025 in. (0.64 mm) Clearance between Locating Tool and Pinion Gear
d - Add or Subtract Shims Here
NOTE: Bearing Preload Tool should remain installed on drive shaft after setting pinion
gear depth as it is required to properly check forward gear and reverse gear backlash.
90-855347R02 NOVEMBER 2002 Page 6B-41

Reverse Gear
DETERMINING REVERSE GEAR BACKLASH
NOTE: Reverse gear backlash is adjustable using shims; it can be checked as follows:
1. Install Driver Tool into reverse gear assembly.
2. Slide Pilot Ring over driver tool and seat pilot ring against inner ledge in gearcase.
3. Thread Retainer into gearcase cover nut threads.
4. Torque Screw to 45 Ib. in. (5 Nm) against driver tool.
d b
e a
c
51884
a - Driver Tool (91-18605)
b - Pilot Ring (91-18603)
c - Inner Ledge
d - Retainer (91-18604)
e - Screw (91-18602) [Torque to 45 lb. in. (5 Nm)]
5. Thread stud adapter (from Bearing Preload Tool) all the way onto stud.
6. Install the following:
a. Backlash Indicator Tool
b. Dial Indicator Holder
c. Dial Indicator
7. Position dial indicator pointer on line marked “1” on Backlash Indicator Tool, if gear
ratio is 1.87:1 (15 teeth on pinion gear), or on line marked “2” on Backlash Indicator
Tool, if gear ratio is 2:1 (14 teeth on pinion gear).
8. Lightly turn drive shaft back-and-forth (no movement should occur at propeller shaft).
Page 6B-42 90-855347R02 NOVEMBER 2002

9. Dial Indicator registers amount of backlash, which should be 0.030 in. to 0.050 in.
(0.76 mm to 1.27 mm).
d f
c
e
a
51880
a - Stud Adaptor (from 91-14311A1)
b - Stud
c - Backlash Indicator Tool (91-78473)
d - Dial Indicator Holder (91-89897)
e - Dial Indicator (91-58222A1)
f - Dial Indicator Pointer
NOTE: If reverse gear backlash is not within specifications, then gearcase is not properly
assembled or components within gearcase are excessively worn and must be replaced
before returning gearcase to service.
10. Remove Driver Tool, Pilot Ring, Retainer and Screw from gearcase.
Forward Gear
DETERMINING FORWARD GEAR BACKLASH
1. Install a load washer over a propeller shaft so that it seats against the REAR shoulder
of the clutch spline teeth.
b
a c 55088
a - Load Washer (12-37429)
b - Shoulder
c - Propeller Shaft (44-93003)
90-855347R02 NOVEMBER 2002 Page 6B-43

2. Assemble bearing carrier, bearing adaptor, thrust washer, thrust bearing, and forward
gear onto propeller shaft.
3. Position shim against shoulder in gearcase.
e c
g
h
a
f d b 55103 55104
a - Bearing Carrier
b - Bearing Adaptor
c - Thrust Washer
d - Thrust Bearing
e - Forward Gear
f - Shim (PLACE IN GEARCASE FIRST)
g - Shoulder
h - Shim
4. Insert entire propeller assembly into gearcase.

5. Install tab washer and cover nut. Torque cover nut to 100 Ib. ft. (135.5 Nm) to seat
forward gear assembly in gearcase.
NOTE: Drill a 3/8 in. (22.2 mm) diameter hole through the side (propeller nut end) of a 5
in. x 2 in. (127 mm x 50.8 mm) long piece of PVC pipe. A screwdriver may be inserted
through pipe into propeller shaft splines to prevent PVC pipe from turning while tightening
retaining nut.
6. Install a 5 in. x 2 in. (127 mm x 50.8 mm) long piece of PVC pipe (obtain locally) over
propeller shaft and secure it against the bearing carrier with a flat washer and nut.
a d
f h
g
b c e
i j k 51882
a - Prop Nut f - Bearing Carrier
b - Flat Washer g - Prop Shaft
c - PVC Pipe [5 in. x 2 in. h - Bearing Adaptor
(127 mm x 50.8 mm)] i - Shim
d - Cover Nut j - Forward Gear
e - Tab Washer k - Load Washer
Page 6B-44 90-855347R02 NOVEMBER 2002

7. Tighten nut to 45 lb. in. (5 Nm). This will seat the forward gear against the forward
thrust bearing and tends to hold the propeller shaft from moving when measuring
backlash.
NOTE: Bearing Preload Tool (91-44307A1) should still be installed from having previously
been used to determine pinion gear depth and reverse gear backlash. If it is not still installed
on gearcase, refer to DETERMINING PINION GEAR DEPTH, for the proper installation
procedure.
8. With the proper preload applied to the propeller shaft and the drive shaft, rotate the
drive shaft clockwise 5 to 10 complete revolutions. This will seat the forward gear and
upper drive shaft bearings and thus provide the most accurate backlash readings.
9. If not previously installed:
a. Thread stud adaptor (from Bearing Preload Tool) all the way onto stud.
b. Install the following:
(1.) Backlash Indicator Tool
(2.) Dial Indicator Holder
(3.) Dial Indicator
10. Position dial indicator pointer on line marked “1” on BACKLASH INDICATOR TOOL,
if gear ratio is 1.87:1 (15 teeth on pinion gear), or on line marked “2” on BACKLASH
INDICATOR TOOL, if gear ratio is 2:1 (14 teeth on pinion gear).
d f
c
e
a
51880
a - Stud Adaptor (from 91-44307A1)
b - Stud
c - Backlash Indicator Tool (91-78473)
d - Dial Indicator Holder (91-89897)
e - Dial Indicator (91-58222A1)
f - Dial Indicator Pointer
11. Gently rock drive shaft back and forth to determine forward gear backlash.
NOTE: Models with 1.87:1 Ratio = 0.018 in. to 0.027 in. (0.46 mm - 0.69 mm) backlash.
NOTE: Models with 2.00:1 Ratio = 0.015 in. to 0.022 in. (0.38 mm - 0.56 mm) backlash.
90-855347R02 NOVEMBER 2002 Page 6B-45

12. If backlash is less than specification, a larger shim should be installed. Conversely, if
the backlash indicated is greater than specification, a smaller shim should be installed.
NOTE: By adding or subtracting 0.002 in. (0.051 mm) shim, the backlash will change ap-
proximately 0.002 in. (0.051 mm).
51882
a - Shim
13. If forward gear backlash is within specifications, then Bearing Preload Tool, Dial Indi-
cator, Backlash Indicator Tool/Dial Indicator Holder, PVC pipe, forward gear assem-
bly, bearing adaptor, bearing carrier and test propeller shaft can all be removed from
the gearcase.
Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier
REASSEMBLY
1. Position sliding clutch onto propeller shaft. The grooved rings are for manufacturing
purposes only and may be positioned towards either gear. Cross pin hole and detent
hole in sliding clutch must line up with cross pin slot and detent notch in propeller shaft.
a
d f
b
e g
c 51913
a - Sliding Clutch
b - Propeller Shaft
c - Grooved Rings
d - Cross Pin Hole
e - Detent Hole
f - Cross Pin Slot
g - Detent Notches
Page 6B-46 90-855347R02 NOVEMBER 2002

2. Place a small amount of 2-4-C with Teflon on actuator rod and install cam follower.
b a
a - Actuator Rod
b - Cam Follower
3. Slide clutch actuator assembly into propeller shaft. Align cross pin slot in actuator rod
with cross pin slot in clutch/propeller shaft.
a b d c e
51875
a - Cam Follower
b - Clutch Actuator Rod
c - Propeller Shaft
d - Cross Pin Slot
e - Clutch/Propeller Shaft
4. Insert cross pin through sliding clutch, propeller shaft and actuator rod forcing cross
pin tool out.
a
51875
a - Cross Pin
5. Apply a small amount of 2-4-C with Teflon to rounded end of detent pin. Position detent
pin in detent pin hole of sliding clutch with rounded end of pin toward propeller shaft.
a b
51879
a - Detent Pin
b - Detent Pin Hole
c - Sliding Clutch
90-855347R02 NOVEMBER 2002 Page 6B-47

6. Install cross pin retaining spring onto sliding clutch as follows:

IMPORTANT: DO NOT over-stretch retaining spring when installing onto sliding
clutch.
a. Spirally wrap spring into groove on sliding clutch.
b. Position spring in groove so that straight end of spring is against the side of groove.
7. Place gear housing in a soft jaw vise with the drive shaft in a vertical position.
8. Coat cam pocket of cam follower with 2-4-C with Teflon.
9. Place shift cam into cam pocket of cam follower with numbered side of cam facing up.
10. Slide propeller shaft assembly into reverse gear assembly.
b a
c e d
55095 55096
a - Cam Pocket
b - Cam Follower
c - Shift Cam
d - Shift Cam (Position as Shown)
e - Gear Housing
11. Apply a light coat of 2-4-C with Teflon to the threads of the shift shaft bushing.
12. Insert shift shaft down shift shaft hole in gear housing and into shift cam. It may be
necessary to rotate shift shaft back and forth slightly in order for splines of shift shaft
to match up with splines of shift cam. Thread bushing into position, but do not tighten
down at this time.
51867
a - Shift Shaft Bushing
b - Shift Shaft
Page 6B-48 90-855347R02 NOVEMBER 2002

13. Install appropriate spacer shim into the gear housing.

14. Apply Premium Lubricant to to thrust bearing and install thrust bearing and thrust race
onto forward gear bearing adaptor.
a c
55220
50782
a - Shim
b - Bearing Adaptor
c - Thrust Washer
d - Thrust Bearing
15. Insert Forward Gear Installation Tool into forward gear/bearing adaptor assembly.
16. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying
downward pressure to bearing adaptor, remove installation tool from assembly.
55221
55202
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear/Bearing Adaptor Assembly
c - Forward Gear Bearing Adaptor
90-855347R02 NOVEMBER 2002 Page 6B-49

17. Install thrust race on top of bearing adaptor.

18. Apply Premium Gear Lubricant to small thrust bearing and install bearing on thrust
race.
55107 55108
a - Thrust Race
b - Thrust Bearing
19. Install thrust collar with its STEPPED SIDE DOWN toward the small thrust bearing.
20. Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the
keepers. Install the 2 keepers into the groove and lower the propeller shaft.
a e
55109 55110
a - Thrust Collar
b - Thrust Bearing
c - Propeller Shaft
d - Keepers (2)
e - Thrust Collar
Page 6B-50 90-855347R02 NOVEMBER 2002

21. Install second thrust collar with its stepped side UP.
22. Apply Premium Gear Lubricant to the second thrust bearing and install it on top of the
second thrust collar.
b
a
c
55112
a - Thrust Collar
b - Thrust Bearing
c - Thrust Collar
23. Apply Premium Gear Lubricant to to second small thrust bearing race and install race
to the surface inside of the bearing carrier.
24. Apply 2-4-C with Teflon to bearing carrier O-ring. Install O-ring onto bearing adaptor.
b
50779 55113
a - Thrust Race
b - Bearing Carrier Race Surface
c - O-ring
90-855347R02 NOVEMBER 2002 Page 6B-51

25. Apply 2-4-C with Teflon to:

a. Outer diameter of bearing carrier which contacts gearcase.
b. Space between carrier oil seals.
26. Apply Premium Gear Lubricant to bearing carrier needle bearing.
27. Install bearing carrier into gear housing.
28. Verify bearing carrier keyway is aligned with gear housing keyway and install bearing
carrier key.
29. Place tab washer against bearing carrier.
b
a
51885
55114
a - Bearing Carrier
b - Tab Washer
30. Apply 2-4-C with Teflon to threads of cover nut and install cover nut in gear housing.
Verify that the word “OFF” and arrow are visible.
NOTE: Before torquing bearing carrier cover nut, gearcase should either be mounted in
a stand specifically designed for holding gearcases or bolted to a drive shaft housing to
avoid possible damage to the gearcase.
31. Using Gear Housing Cover Nut Tool, torque cover nut to 210 Ib. ft. (285 Nm).
a b
51911
a - Gear Housing Cover Nut Tool (91-61069)
b - Retainer Nut
Page 6B-52 90-855347R02 NOVEMBER 2002

32. Bend one lock tab of tab washer into cover nut (only one will align).
33. Bend remaining tabs of tab washer toward front of gear housing.
34. Use Shift Shaft Bushing Tool and torque shift shaft bushing to 50 Ib. ft. (68 Nm).
51882
a - Shift Shaft Bushing Tool (91-31107)
b - Shift Shaft Bushing
Water Pump
1. Install oil seals into water pump base, as follows:
a. Place water pump base on a press.
b. Just before installing each seal apply Loctite 271 on outside diameter of oil seal.
c. With a suitable mandrel, press the smaller diameter oil seal into pump base with
lip of oil seal toward impeller side of base.
d. With a suitable mandrel, press the larger diameter oil seal into pump base with lip
of oil seal toward gear housing side of base.
e. Wipe any excess Loctite from oil seals and water pump base.
2. Install O-ring into O-ring groove of water pump base. Lubricate O-ring and oil seals
with 2-4-C with Teflon.
c
b
51869
a - Mandrel
b - Oil Seal (Smaller OD)
c - O-Ring Groove
90-855347R02 NOVEMBER 2002 Page 6B-53

3. Install divider block if removed. Use RTV 587 Silicone Sealer to seal seams between
divider block and gear housing.
4. Install a new water pump base gasket and install water pump base.
b c 51866
51878
a - Divider Block
b - Water Pump Base
c - Gasket
d - Hole (MUST be positioned as shown)
5. Install the following in order: Pump base to face plate gasket, face plate to pump cover
gasket. Gaskets and face plate are indexed by dowel pin location and must be in-
stalled correctly.
b
b
cc
51868
a - Gasket (Water Pump Base to Face Plate)
b - Face Plate
c - Gasket (Face Plate to Water Pump Cover)
6. Place impeller drive key on flat of drive shaft. Hold key on drive shaft with a small
amount of 2-4-C with Teflon.
IMPORTANT: When completing gear housing repair that requires removal of water
pump impeller, it is recommended that the impeller be replaced. If it is necessary
to reuse the impeller, DO NOT install in reverse to original rotation or premature
impeller failure will occur. Original rotation is clockwise.
Page 6B-54 90-855347R02 NOVEMBER 2002

CAUTION
A visual inspection of impeller drive key MUST BE made to determine that drive
key is on flat of drive shaft after impeller is installed. If key has moved off flat of
drive shaft, repeat Steps 7 and 8.
7. Slide impeller down driveshaft to impeller drive key. Align drive key with keyway in the
center hub of impeller, and slide impeller over drive key.
8. If removed, install new water pump insert into pump cover as follows:
a. Apply Perfect Seal to water pump insert area of pump cover.
b. Install the water pump insert into pump cover, being sure that the tab on the insert
enters recess in pump cover.
c. Wipe any excess Perfect Seal from insert and cover.
NOTE: If 2 holes were drilled in top of water pump cover to aid in removal of insert, fill holes
with RTV 587 Silicone Sealer (or equivalent). Allow to cure 24 hours prior to operating
engine.
9. Install water tube seal into pump cover. Plastic side of seal goes into cover first.
10. Reinstall water tube guide into water pump cover.
11. Apply a light coat of 2-4-C with Teflon to inside of water pump insert.
12. Position assembled water pump cover over driveshaft and lower over water pump
studs. Rotate driveshaft in a clockwise direction (viewed from top), while pushing
down on pump cover to ease impeller entry into cover.
13. Install water pump cover retainer washers, nuts and bolt.
CAUTION
DO NOT over-torque nuts and bolt, as this could cause cover to crack during
operation.
14. Torque water pump nuts to 50 Ib. in. (6.0 Nm), and water pump bolt to 35 Ib. in. (4 Nm).
15. Install centrifugal slinger over driveshaft and down against pump cover.
c 51874
a - Water Tube Guide
b - Water Tube Seal
c - Nuts, Bolts and Washers
90-855347R02 NOVEMBER 2002 Page 6B-55

Gear Lubricant Filling Instructions

1. Remove any gasket material from Fill and Vent screws and gear housing.
2. Install new gaskets on Fill and Vent screws.
IMPORTANT: Never apply lubricant to gear housing without first removing Vent
screw, or gear housing cannot be filled because of trapped air. Fill gear housing
ONLY when housing is in a vertical position.
3. Slowly fill housing through Fill hole with Premium Gear Lubricant until lubricant flows
out of Vent hole and no air bubbles are visible.
4. Install Vent screw into Vent hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling Fill screw.
5. Remove grease tube (or hose) from Fill hole and quickly install Fill screw into Fill hole.
Installing Gear Housing to Drive Shaft Housing
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from
engine before installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt lock lever.
2. Apply a light coat of 2-4-C with Teflon onto driveshaft splines.
CAUTION
DO NOT allow lubricant on top of drive shaft. Excess lubricant, that is trapped in
the clearance space, will not allow drive shaft to fully engage with crankshaft.
Subsequently, tightening the gear housing nuts (while excess lubricant is on top
of drive shaft) will load the drive shaft/crankshaft and damage the powerhead
and/or gear housing. Top of drive shaft is to be wiped free of lubricant.
3. Apply a light coat of 2-4-C with Teflon onto shift shaft splines. (DO NOT allow lubricant
on top of shift shaft.)
4. Apply a thin bead of RTV 587 Silicone Sealer against the top of divider block.
5. Insert trim tab bolt into hole in rear of gear housing to driveshaft housing machined
surface.
6. Shift gear housing into forward gear and place guide block anchor pin into forward
gear position.
a
51900
a - Guide Block Anchor Pin
Page 6B-56 90-855347R02 NOVEMBER 2002

7. Position gear housing so that the drive shaft is protruding into drive shaft housing.
NOTE: If, while performing Step 8, the drive shaft splines will not align with crankshaft
splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear
housing is being pushed toward drive shaft housing.
8. Move gear housing up toward drive shaft housing while aligning shift shaft splines and
water tube with water tube guide (in water pump cover).
9. Place flat washers onto studs (located on either side of drive shaft housing). Start a
nut on these studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab recess. DO NOT tighten bolt at this
time.
11. Recheck shift shaft spline engagement and correct if necessary.
IMPORTANT: Do not force gearcase up into place with attaching nuts.
12. Evenly tighten the 2 nuts which were started in Step 9. Torque to listing in Torque
Specifications, preceding.
13. After 2 nuts (located on either side of drive shafthousing) are tightened, check shift
operation as follows:
a. Place guide block anchor pin into forward gear position while turning prop shaft.
Rotate flywheel clockwise (viewed from top); propeller shaft should rotate clock-
wise.
b. Place guide block anchor pin into NEUTRAL position. Propeller shaft should rotate
freely clockwise/counterclockwise.
c. Place guide block anchor pin into REVERSE gear position. Rotate flywheel
clockwise (viewed from top). Propeller shaft should rotate counterclockwise.
IMPORTANT: If shifting operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
14. Install washers and nuts onto studs (located on bottom center of anti-cavitation plate).
Torque to listing in Torque Specifications, preceding.
15. Install special flat washer and nut on stud at leading edge of drive shaft housing.
Torque to listing in Torque Specifications, preceding.
16. Torque bolt (started in Step 10) to listing in Torque Specifications, preceding.
17. Install trim tab, adjust to position in which it had previously been installed, and tighten
the bolt securely.
18. Install plastic cap into trim tab bolt opening at rear edge of drive shafthousing.
90-855347R02 NOVEMBER 2002 Page 6B-57

Propeller Installation
WARNING
When installing or removing propeller, because of the engine’s ease in starting,
VERIFY that the remote control is in NEUTRAL position and that the key switch
is “OFF.” Place a block of wood between the anti-cavitation plate and propeller
to prevent accidental starting and to protect hands from propeller blades while
removing or installing nut.
1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with
one of the following products:
a. Anti-Corrosion Grease
b. Special Lubricant 101
c. 2-4-C with Teflon
d. Perfect Seal
2. Place forward thrust hub over propeller shaft with shoulder side toward propeller.
3. Place propeller on propeller shaft and slide it up against thrust hub.
a - Forward Thrust Hub

b - Propeller Shaft
4. Place continuity washer (if equipped) onto shoulder of rear thrust hub.
5. Place rear thrust hub, tab washer and propeller nut on propeller shaft.
6. Thread propeller nut onto propeller shaft until nut is recessed into tab washer.
7. After propeller nut is recessed into tab washer, tighten nut securely [minimum of 55
Ib. ft. (74.5 Nm) torque].
8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller
nut. (If tab washer tabs do not align with slots, continue to tighten propeller nut to
obtain alignment. DO NOT loosen nut to align tabs.)
CAUTION
DO NOT misinterpret propeller shaft movement with propeller movement. If pro-
peller and propeller shaft together move forward and aft, this is normal; however,
propeller should not move forward and aft on propeller shaft.
Page 6B-58 90-855347R02 NOVEMBER 2002

9. After first use, retighten propeller nut and again secure with tab washer (Steps 7 and
8, preceding). Propeller should be checked periodically for tightness, particularly if a
stainless steel propeller is used.
b 51916
a - Continuity Washer (If Equipped)
b - Rear Thrust Hub
c - Tab Washer
d - Propeller Nut
90-855347R02 NOVEMBER 2002 Page 6B-59

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LEFT HAND NON-RATCHETING

Gear Housing Specifications (Counter Rotation)

Gearcase Lubricant Capacity

All Ratios 22.5 fl. oz. (665.4 ml)

90-855347R02 NOVEMBER 2002 Page 6B-1

2. Gear Housing Cover Nut Tool 91-61069

3. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716

4. Slide Hammer Puller 91-34569A1

7. Puller Rod 91-31229 and Nut 91-24156

Page 6B-2 90-855347R02 NOVEMBER 2002

8. Puller Plate 91-29310

10. Driver Rod 91-37323

11. Universal Puller Plate 91-37241

12. Drive Shaft Holding Tool 91-34377A1 or 91-90094

13. Oil Seal Driver 91-31108

14. Forward Gear Bearing Tool 91-86943

15. Pinion Gear Locating Tool 91-12349A2 or 91-74776

16. Backlash Indicator Rod 91-78473

17. Dial Indicator 91-58222A1

90-855347R02 NOVEMBER 2002 Page 6B-3

18. Bearing Retainer Tool 91-43506

19. Mandrel 91-92788

20. Mandrel 91-15755

21. Dial Indicator Holder 91-89897

22. Bearing Preload Tool 91-14311A1

23. Propeller Shaft 44-93003 and Load Washer 12-37429

24. Forward Gear Installation Tool 91-815850

Page 6B-4 90-855347R02 NOVEMBER 2002

90-855347R02 NOVEMBER 2002 Page 6B-5

Gear Housing (Drive Shaft)(Counter Rotation)

Page 6B-6 90-855347R02 NOVEMBER 2002

Gear Housing (Drive Shaft)(Counter Rotation)

90-855347R02 NOVEMBER 2002 Page 6B-7

Gear Housing (Prop Shaft)(Counter Rotation)

7 Loctite 271 Thread Locker 94 Anti-Corrosion Grease

Page 6B-8 90-855347R02 NOVEMBER 2002

Gear Housing (Prop Shaft)(Counter Rotation)

90-855347R02 NOVEMBER 2002 Page 6B-9

Gear Housing (Prop Shaft)(Counter Rotation)

7 Loctite 271 Thread Locker 94 Anti-Corrosion Grease

Page 6B-10 90-855347R02 NOVEMBER 2002

Gear Housing (Prop Shaft)(Counter Rotation)

90-855347R02 NOVEMBER 2002 Page 6B-11

General Service Recommendations

Page 6B-12 90-855347R02 NOVEMBER 2002

Removal, Disassembly, Cleaning and Inspection of Counter

90-855347R02 NOVEMBER 2002 Page 6B-13

7. Remove 2 locknuts from bottom middle of anti-cavitation plate.

8. Remove locknut from the front gear housing mounting stud.

Page 6B-14 90-855347R02 NOVEMBER 2002

DRAINING AND INSPECTING GEAR HOUSING LUBRICANT

90-855347R02 NOVEMBER 2002 Page 6B-15

REMOVAL AND DISASSEMBLY

Page 6B-16 90-855347R02 NOVEMBER 2002

90-855347R02 NOVEMBER 2002 Page 6B-17

Bearing Carrier and Propeller Shaft Removal

4. Remove gear housing retainer nut with Retainer Nut Tool.

Page 6B-18 90-855347R02 NOVEMBER 2002

SHIFT SHAFT REMOVAL