Service Manual 40-90 HP.E-TEC Gearcase [Gearcase Removal And Installation]

Gear case Removal

To prevent accidental starting while servicing, twist and remove all spark plug leads. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

Remove pin and washer from shift rod lever to release the lower shift rod.

1. Shift rod screw

Note where the index mark on the gear case aligns with the index number of the adjustable trim tab so the trim tab can be installed in the same position. Remove the trim tab retaining screw and trim tab from the gear case.

1. Trim tab
2. Trim tab retaining screw

Remove the forward screw with washer and recessed retaining screw.

1. Forward screw
2. Recessed screw

Remove the four gear case retaining screws.

1. Gear case retaining screws

Remove the gear case assembly from the exhaust housing, being careful not to bend the shift rod.

Gear case Installation

During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

Before installing gear case, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 336.

Coat the driveshaft splines with Moly_ Lube. DO NOT coat top surface of the driveshaft as lubricant may prevent seating of the driveshaft in the crank shaft.

Apply Adhesive 847 to the exhaust housing seal’s
inner surface. Place the seal on the exhaust housing. Apply Triple-Guard grease to the seal’s outer
surfaces.
Slide the gear case into place, making sure:
• Driveshaft engages the crankshaft.
• Inner exhaust housing installs correctly.
• Shift rod does not turn and is positioned properly in shift shaft connection area.
Apply Gasket Sealing Compound to threads of the
gear case retaining screws. Tighten the screws to
a torque of:
• 3/8 in. screws – 18 to 20 ft. lbs. (24 to 27 N·m)
• 7/16 in. screw – 28 to 30 ft. lbs. (38 to 40 N·m)

• 5/16 in. screw – 10 to 12 ft. lbs. (13.5 to 16 N·m)

1. 3/8 in. screws

1. 7/16 in. screw
2. 5/16 in screw

Apply Gasket Sealing Compound to threads of the trim tab screw. Install and align the trim tab with the index marks noted prior to disassembly. Tighten the trim tab screw to a torque of 35 to 40 ft. lbs. (47 to 54 N·m). For adjustment, refer to Trim Tab Adjustment on p. 76.

1. Trim tab screw

Place the shift rod in the shift rod lever. Install the retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Shift rod screw

To prevent loss of operator control, check for proper shifting operation and adjust, if necessary.

IMPORTANT:

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

Disassembly

Remove the four impeller housing screws.

1. Impeller housing screws

Slide the water pump off the driveshaft. Remove the impeller drive key, impeller plate, and gasket. Discard the gasket.

1. Impeller plate
2. Drive key

Remove all the parts from the housing.

Inspection

Check impeller for overheating, hub separation, and other wear or damage.

Check liner and wear plate for scoring, distortion, and impeller material transfer.

Inspect the housing for cracks or melting.

Make sure gasket surface is clean and smooth.