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Removal of OMC Stringer Complete Outdrive

Manufacturer BRP Marine
Engine Type I/O
Repair Time 1 to 2 hours
Repair Difficulty Medium

1. Tilt the vertical drive enough to expose the shift cable retainer on the intermediate, then remove the retainer screw and lockwasher.

2. Tilt the vertical drive down to the position shown in Figure 7-2, just before the locating pins enter their seats.

3. Disconnect the battery to prevent grounding the shift cable core wires on electrical components during removal of the vertical drive.

Core wires must not come in contact with live electrical components that can suddenly actuate the vertical drive tilt mechanism or produce sparks that may ignite gas vapors. Contact can also result in damage to the core wires that would necessitate replacement of the entire shift cable assembly. Continued use of shift cable with damaged core wires may result in core wire breakage causing operator to lose control of boat.

4. Remove shift cable from shift converter housing as follows:

a. Remove converter housing from mounting studs and bring it up along the port side of the intake manifold. This will allow easier access for service.
b. Remove the four cover screws and allow the cover to swing down about the shift arm as shown in Figure 7-3. Do not remove the shift arm.

5. Remove the plastic cable guide and the two hitch pins.
d. Release tension on the shift cables as follows: raise tensioner pawls, push in on the shift cable until it stops, insert cotter pin through converter housing and release cable. See Figure 7-3A. The shift cables will now have enough slack to be removed from the pulley segment.

Raise pawls only far enough to disengage tensioner. Additional displacement of pawls may cause the torsion spring to deform or dislocate. This will result in loss of cable tension and may cause a shift malfunction leading to operator losing control of boat.

e. Increase slack by rotating pulley to left. Remove the upper shift core wire from the idler pulley and segment pulley outer groove. Then, remove wire end fitting from segment pulley pocket. See Figure 7-3B. Next, rotate segment pulley to; right to increase slack. in lower cable, and remove lower wire from segment pulley and end fitting from pocket.

f. Carefully pull the shift cable and core wires out of the housing.

6. Remove the cap screws, port and starboard that hold the pivot cap covers to the intermediate housing. See Figure 7-5. Remove pivot cap cover, gaskets. plates, and O-rings.

7. Pry off rubber bumpers.

8. Use 9/16" deepwell socket to loosen the two pivot cap screws, port and starboard. See Figure 7-7. While supporting the vertical drive, remove the pivot cap screws and pivot cap. Allow vertical drive to balance on tilt quadrant gear.

9. Lubricate shift cable with OMC Marine Cleaner or a soapy water solution and carefully pull shift cable and vertical drive from intermediate housing. Mark both ball gears for correct tooth engagement for reassembly of vertical drive to intermediate housing.

After removing the vertical drive, make sure the pivot liners are retained on the pivot trunnions to protect their machined surface. This liner will come off with the drive unit. It is also important that the pivot caps be kept in a safe place. The top of the intermediate housing and the pivot caps have identification marks on them. They are marked "R" and "L" for right and left hand. It is important that these are matched correctly upon reinstallation. The caps must never be interchanged from right to left or from unit to unit. Liners must be installed with slot at 180 degrees from the grease fitting on the pivot cap.

  1. Check the alignment of the pivot cap faces on the intermediate housing and the pivot trunnions on the vertical drive. A severe blow to the vertical drive from any direction could result in misalignment and rapid wear to ball gears, shafts and bearings. To check, use an alignment tool such as Ouadriel OAT 4. Refer to Section 6 for inspection procedures.

0775631 - Johnson/Evinrude, OMC MARINE CLEANER QT