Service Manual 5007213_Evinrude E-TEC 115-200 HP Gearcase [Assembly]

Install water intake screens. Torque screws to 60 to 84 in. lbs. (7 to 9.5 N•m).

1. Water intake screen

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 properly positioned. Insert the shaft assembly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing.

1. Pin

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 around shift rod cover’s full circumference.

1. O-ring

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 (25” models)

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. Position 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 locator pin hole in the gearcase.

Apply Ultra Lock to the threads of the shift rod cover screws. Install the screws. Torque the screws to 60 to 84 in. lbs. (7 to 9.5 N•m).

Refer to DRIVESHAFT SHIMMING on p. 332

“S2” TYPE GEARCASE

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

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

Push down on shift rod to move the clutch dog to reverse position. Pull propeller shaft aft to disengage from forward gear and shift housing. Allow shaft to drop against lower gearcase housing. This will allow the installation of the pinion gear.

1. Propeller shaft

IMPORTANT: Forward gear and thrust bearing and washer can become misaligned. Make sure forward thrust washer and thrust bearing and forward gear are properly aligned with shift housing before continuing gearcase assembly.

Install pinion gear in gearcase housing.

Install driveshaft with thrust bearing, thrust washer, and correct shim(s) in gearcase housing. Position pinion on lower driveshaft.

Position pinion screw in lower driveshaft and thread into pinion.

IMPORTANT: Temporarily install bearing housing for support during pinion torque procedure.

Insert Lower Driveshaft Spline Tool, P/N 5007052, into lower driveshaft.

1. Lower Driveshaft Spline Tool

Insert Lower Driveshaft Wrench, P/N 352877, through Lower Driveshaft Spline Tool and lower driveshaft. Seat hex tip of wrench in head of pin ion screw.

1. Wrench, hex tip

IMPORTANT: Make sure Lower Driveshaft Wrench is fully seated in head of pinion screw.

Use a long 3/4 in. combination wrench to hold Driveshaft Spline Tool and a 1/2” drive torque wrench to turn the Lower Driveshaft Wrench in a clockwise direction. Torque pinion screw to 37 to 41 ft. lbs. (50 to 56 N•m).

Temporarily remove the four driveshaft bearing housing screws with washers and bearing housing.

To install upper driveshaft into lower driveshaft, position new retainers (circlip type) on upper driveshaft as shown.

1. Retainer(s)

Hold lower retainer and align upper driveshaft with lower driveshaft. Force upper driveshaft down until seated. Driveshaft should lock in place.

Upper Driveshaft Installation

Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing on p. 326. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft.

1. Seal protector

Install washers on the driveshaft bearing housing screws. Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 N•m).

1. Driveshaft bearing housing screws

“O,” “L,” AND “M” TYPE GEARCASES

Refer to DRIVESHAFT SHIMMING on p. 332 before proceeding.

Position the driveshaft thrust bearing, thrust washer, and shim(s) (selected earlier) on the driveshaft, exactly in order shown.

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

Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing on p. 326. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft.

1. Seal protector

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

Washer must be snapped into recess of pinion gear.

1. Washer

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.

Lightly coat the threads of a new pinion nut with outboard lubricant and install on the driveshaft using Pinion Nut Starting Tool, P/N 342216. Turn the driveshaft by hand to engage the nut. Hand tighten pinion nut and remove the pinion nut starting tool. Proceed to next step and then torque procedure.

Install washers on the driveshaft bearing housing screws. Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 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 torque the pinion nut to 100 to 110 ft. lbs. (136 to 149 N•m).

1. Holding socket
2. Pinion holder
3. Retainer

Oil and install thrust bearing and thrust washer on hub of reverse gear. Slide the reverse 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, aligning screw holes with retainer slots in gearcase.

Housing must be completely seated to install retainer tabs.

Retainer Tab Notch

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

1. Retainer tab screws

“O,” “L,” AND “M” TYPE GEARCASES

Loosen retainer screws 1/4 turn.

Install wedge, screw, and washer. Apply Ultra Lock to threads and torque screw 15 to 20 in. lbs. (1.7 to 2.3 N·m).

Re-torque 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:

• LEAK TEST on p. 308
• WATER PUMP on p. 311
• SHIFT ROD ADJUSTMENT on p. 314
• REMOVAL AND INSTALLATION on p. 308
• LUBRICANT on p. 307
• Propeller Hardware Installation on p. 74
• Trim Tab Adjustment on p. 77

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