Service Manual 5008330_55 HP MFE Gearcase [Gearcase Assembly]

Shift Housing, Gear, and Propeller Shaft Installation

Push shifter detent into farthest downward position. Tip the rear of the gear case 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 gear case while aligning shift housing pin with hole in forward end of gear case housing.

1. Pin 006648

Shift Rod Housing Installation

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

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

1. Cover gasket

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 gear case.

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).

Place the cover seal on the shift rod cover.

1. Cover seal 002514

Pinion Gear and Driveshaft Installation

Refer to DRIVESHAFT SHIMMING on p. 255 before proceeding. Install new seals in driveshaft bearing housing.
Refer to Driveshaft Bearing Housing Service on p. 252.
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)

Lightly apply Gasket Sealing Compound to the gear case area that contacts mounting flange of the driveshaft bearing housing. Do not coat inside bearing housing bore surface of the gear case.

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 gear case. Insert the driveshaft into the gear case and through the pin ion gear. Using Driveshaft Seal Protector, P/N 312403, slide the driveshaft bearing housing onto the driveshaft and into position in the gear case. Align the embossed word “FRONT” toward the shift rod. Do not install screws at this time.

1. Seal protector

Lightly coat the threads of a new pinion nut with outboard lubricant. Use Pinion Nut Starting Tool, P/N 320675, 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 96 to 120 in. lbs. (11 to 14 N·m).

1. Driveshaft bearing housing screws

Use Driveshaft Holding Socket, P/N 334995, and an 11/16 in. open-end wrench, to tighten the pin ion nut to a torque of 40 to 45 ft. lbs. (54 to 60 N·m). Pad handle of the wrench to prevent dam age to gear case.

1. Holding socket
2. 11/16 Wrench

Place the small thrust washer in recess of the reverse gear.

1. Small thrust washer

Oil and install thrust bearing and larger 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

Slide the bearing housing retainer plate into position over the propeller shaft.

1. Retaining ring
   Using Retaining Ring Pliers, P/N 331045, install the two retaining rings.

Retaining rings are under extreme pressure during installation. Wear safety glasses and proceed with care to avoid unsnapping the ring from the pliers.

Make sure the retaining rings are seated in the grooves in the gear case.

1. Retaining ring

Thread two Guide Pins, P/N 383175, into the retainer plate to align holes in the plate with holes in the propeller shaft bearing housing. Do not thread guide pins more than two turns into the retainer plate.

1. Guide pin

Install O-ring in groove in the bearing housing. Lightly apply Gasket Sealing Compound to the O-ring flange and aft support flange of the bearing housing. Do not allow sealer to contact either for ward thrust surface or bearings in the housing.

Align the bearing housing on the guide pins with the word “UP” toward the top. Place the housing into gear case and tap the housing with a soft face mallet to seat the O-ring.

Apply Gasket Sealing Compound to the threads and seals of the four propeller housing retaining screws. Install two of the screws into the bearing housing finger tight. Remove the guide pins and install the remaining two screws. Tighten all four screws to a torque of 120 to 140 in. lbs. (14 to 16 N·m).

Final Assembly and Adjustment

To complete gear case assembly, refer to:
• GEAR CASE LEAK TEST on p. 238
• WATER PUMP SERVICE on p. 242
• SHIFT ROD ADJUSTMENT on p. 244
• GEAR CASE REMOVAL AND INSTALLATION on p. 238
• Gear case Lubricant on p. 61
• Propeller Hardware Installation on p. 42
• IMPELLER SERVICE, MJRL MODELS on p. 236
• Trim Tab Adjustment (MRL) on p. 4
During break-in period of a reassembled gear case, change the gear case lubricant between 10 to 20 hours of operation.