Service Manual 40-90 HP.E-TEC Gearcase [Gearcase Assembly 2]

between the gauge bar and the bearing housing between each pair of screw holes. Replace the bearing housing and repeat check if variance is greater than 0.004 in. (0.010 mm).

Check squareness of the pinion to the driveshaft. Hold the shim gauge bar against the bearing housing (between the screw holes) while rotating just the driveshaft and pinion assembly. Measure clearance between the gauge bar and the pinion at several locations. If variance is greater than 0.002 in. (0.050 mm) replace the pinion or driveshaft, as necessary, and repeat check.

Subtract the average clearance measurement from 0.020 in. (0.508 mm) to determine the correct shim thickness required. Select the fewest number of shims to achieve the correct thickness. Remove the driveshaft from the tool and add the required shims between the bearing housing and the thrust washer.

IMPORTANT: Use extreme care when removing bearing housing to avoid damaging the seals. Use Driveshaft Seal Protector, P/N 318674.

Check clearance again. The measurement between the gauge bar and pinion should be 0.020 in. (0.508 mm).

Remove the nut and pinion from the driveshaft. Discard the nut.

Water Intake Screens

Install water intake screens. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1.Water intake screen_

Shift Housing, Gear, and Propeller Shaft Installation

Push shifter detent into farthest downward position. Tip the rear of the gearcase slightly down ward to assist in the installation of the shaft assembly.

Be sure the thrust bearing and the thrust washer are in the proper position. Insert the shaft assembly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing.

Lubricate a new shift rod cover O-ring with Triple- Guard grease. Install the O-ring into the shift rod cover.

IMPORTANT: Make sure O-ring is fully seated in groove.

1.O-ring

2.Groove

Place the shift rod grommet on the shift rod.
Install shift rod spacer under grommet on 25 in. models.

1.Grommet

2.Shift rod spacer

Apply Triple-Guard grease to the threaded end of the shift rod and insert it through the cover. Turn the shift rod while pushing it through the cover to avoid damaging the O-ring.

Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket. Place the gasket on the gearcase.

Thread the shift rod into the shifter detent about four turns.

1.Cover gasket
2.Grommet

Move shift rod from side to side while pushing on the propeller shaft to ensure proper alignment of the bearing housing locator pin into the pin hole in the gearcase.

Apply Gasket Sealing Compound to the threads of the shift rod cover screws. Tighten the screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N•m).

Refer to SHIFT ROD ADJUSTMENT on p. 359.

Refer to DRIVESHAFT SHIMMING on p. 373 before proceeding.

Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing Service on p. 345.

Place the driveshaft thrust bearing, thrust washer, and correct shim(s) on the driveshaft as shown.

1. Thrust bearing
2. Thrust washer
3. Shim(s)

Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase.

1. Seal protector

Adjust shift rod to move clutch dog as far forward as possible. Be sure excess grease is removed from the pinion bearing.

IMPORTANT: The inside taper of the pinion gear and the driveshaft taper MUST be completely free of grease. Clean the tapers with Cleaning Solvent. Use a shop towel free of grease and lint.

Place the pinion gear into the gearcase. Insert the driveshaft into the gearcase and through the pin ion gear.

Lightly coat the threads of a new pinion nut with outboard lubricant. Use Pinion Nut Starting Tool, P/N 342216, to install nut on the driveshaft. Turn the driveshaft by hand to thread the nut on to shaft.

Apply Gasket Sealing Compound to the threads of the driveshaft bearing housing screws. Tighten screws in stages to a torque of 120 to 144 in. lbs.(13.5 to 16.5 N•m).

1. Driveshaft bearing housing screws

Use Driveshaft Holding Socket, P/N 311875, Pin ion Nut Holder, P/N 334455, and Wrench Retainer, P/N 341438, to tighten the pinion nut to a torque of 100 to 110 ft. lbs. (136 to 149 N•m). Pad handle of holder to prevent damage to gear case.

1. Holding socket
2. Pinion holder
3. Retainer

Oil and install thrust bearing and thrust washer on hub of reverse gear. Slide the gear assembly onto the propeller shaft until it engages the pinion gear.

1. Thrust bearing
2. Thrust washer

Lightly apply Gasket Sealing Compound to a new bearing housing O-ring. Install O-ring in groove in the housing.

Install housing into gearcase. Align screw holes with retainer slots in gearcase.
Housing must be completely seated to install retainer tabs.

Retainer Tab Notch 50106a

Install two retainers, washers and screws. Apply Ultra Lock to threads and tighten screws to a torque of 18 to 20 ft. lbs. (24 to 27 N•m).

1. Retainer tab screws

“O” Type Gearcases

Loosen retainer screws 1/4 turn.
Install wedge, screw, and washer. Apply Ultra Lock to threads and tighten screw to a torque of 15 to 20 in. lbs. (1.7 to 2.3 N•m).

Re-tighten two retainer screws to 18 to 20 ft. lbs. (24 to 27 N•m).

Confirm that torque on the wedge screw is 15 to 20 in. lbs. (1.7 to 2.3 N•m).

To complete gearcase assembly, refer to:

• GEARCASE LEAK TEST on p. 331
• WATER PUMP SERVICE on p. 356
• SHIFT ROD ADJUSTMENT on p. 359
• GEARCASE REMOVAL AND INSTALLATION on p. 354
• Gearcase Lubricant on p. 85
• Propeller Hardware Installation on p. 70
• Trim Tab Adjustment on p. 76.

During break-in period of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.