Service Manual 15-30 HP Gearcase [Gearcase Disassembly]

Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).

IMPORTANT: Clean and inspect all parts during disassembly. Replace any damaged parts, seals, O-rings, and gaskets.

Remove the propeller and mounting hardware.

Drain and inspect oil as described in Gearcase Lubricant on p. 34.

Remove gearcase. Refer to GEARCASE REMOVAL AND INSTALLATION on p. 248.

Remove water pump. Refer to WATER PUMP SERVICE on p. 250.

Before disassembling the gearcase, examine the following:

• Gearcase Housing — Check for visible dam age to skeg, strut, anti-ventilation plate, bullet, and mating surface. Check seal areas for visible signs of lubricant leakage.
• Propeller Shaft — Check for bent or damaged shaft. Check for twisted splines and damaged threads.
• Shift Rod — Check for bent, or binding rod.
• Hydrostatic Seal Grooves — Must be in good condition to help prevent propeller ventilation.

1. Hydrostatic seal grooves

• Gearcase Anodes — If anodes have eroded to two-thirds their original size, they must be replaced.

1. Gearcase anode

• Drive Shaft — Check splines for visible dam age, twisting and wear. Severe spline wear indicates the exhaust housing or gearcase has been distorted, possibly by impact damage.

Remove and discard exhaust seal assembly.

1. Seal assembly

Propeller Shaft Bearing Housing Removal

Remove the two propeller shaft bearing housing screws.

1. Screws

Remove the propeller shaft bearing housing from the gearcase using the Universal Puller Set, P/N 378103:

• Puller body, P/N 307636
• Handle, P/N 307638
• Pressing screw, P/N 307637
• Two flat washers, P/N 307639
• Two 1/4-20 x 6 in. screws (obtain locally)

1. Body
2. Handle
3. Pressing screw
4. Washers
5. Screws (obtain locally)

Remove the retaining ring using Retaining Ring Pliers, P/N 331045.

Retaining ring is under extreme pressure during removal and installation. To prevent personal injury, wear safety glasses and proceed with care to avoid unsnapping the ring from the pliers. After the retaining ring is removed far enough from the gearcase to clear the housing, release the tension on the pliers while retaining ring is still around the propeller shaft.

1. Retaining ring

Remove the retainer plate from the gearcase.

1. Retainer plate

Shifter, Gear and Propeller Shaft Removal

Unscrew the lower shift rod from the shifter yoke and remove the shift rod from the gearcase.

1. Lower shift rod

Use long-nose pliers to remove the shift yoke.

Remove the shifter lever pivot pin. Discard the pivot pin O-ring.

1. Shift lever pivot pin

Remove the propeller shaft and reverse gear components from the gearcase.

1. Propeller shaft
2. Reverse gear
3. Thrust washer

IMPORTANT: Shifter detent balls and spring will pop out of the clutch when the propeller shaft is removed.

Use a magnet to locate and remove the two shifter detent balls and one detent spring from the gearcase.

1. Spring and balls

Use long-nose pliers to remove the clutch and shifter lever assembly. Use no force. Tilting the shifter lever slightly will allow you to remove it from the gearcase.

1. Clutch
2. Shifter lever assembly

Remove the forward bearing, forward gear, pinion, pinion thrust bearing, and two pinion thrust washers.

IMPORTANT: Inspect bearings for damage while in place. If bearing is damaged, remove and discard. If the bearing is removed for any reason, it must be replaced.

Driveshaft Seals
Use Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131, to remove the two driveshaft seals. Discard the seals.

Driveshaft Bearing
Use Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131 to remove the driveshaft bearing and sleeve from the gearcase. Discard the bearing.