Service Manual 5008330_55 HP MFE Gearcase [Gearcase Disassembly]

Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

With the gear case in NEUTRAL, rotate the shift rod up or down as necessary for correct adjustment. Once correct height is achieved, rotate rod one half turn or less to direct offset to the rear. Shift Rod Height:

• 21.38 in. (543 mm) ± One-Half Turn

Pre-Disassembly Inspection

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/impeller and mounting hardware.

Drain and inspect oil as described in Gear case Lubricant on p. 61.

Remove gear case. Refer to GEAR CASE REMOVAL AND INSTALLATION on p. 238.

Remove water pump. Refer to WATER PUMP SERVICE on p. 242.

Before disassembling the gear case, examine the
following:
• Gear case Housing — Check for visible damage 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 mis adjusted, bent, or binding rod. A mis adjusted shift rod height can cause shift difficulty, loss of boat and outboard control, and gear case damage.
• Hydro static Seal Grooves — Must be in good condition to help prevent propeller ventilation

1. Hydro static seal grooves

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

1. Gear case anode

• Drive Shaft — Check splines for visible damage, twisting and wear. Severe spline wear indicates the exhaust housing or gear case has been distorted, possibly by impact damage.
• Water Intake Screens — Check for damage and blockage. If screens cannot be cleaned, they must be replaced. Different screens are available and should not be mixed. Refer to correct model parts manual for listing and description.

Propeller Shaft Bearing Housing Removal

Use a 5/16 in. thin wall socket to remove the four screws with O-rings holding the propeller shaft bearing housing.

Remove the propeller shaft bearing housing from the gear case using the following:

• Puller body, screw, and handle from Universal Puller Set, P/N 378103.
• Two 5/16-18 x 8 in. screws, P/N 316982, from Universal Puller Set, P/N 378103.

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

Retaining rings are 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 rings are removed far enough from the gear case 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 gear case.

1. Retainer plate

Remove the larger thrust washer, thrust bearing, and reverse gear from the gear case. Remove the smaller thrust washer located in front of the gear.

MRL Models

1. Larger thrust washer
2. Thrust bearing
3. Reverse gear

MJRL Models

1. Larger thrust washer
2. Thrust bearing
3. Reverse gear

Pinion Gear and Driveshaft Removal

Adjust the shift rod to move the clutch dog as far forward as possible. This will help ease removal of the pinion nut.

Use Driveshaft Holding Socket, P/N 334995, and an 11/16 in. open-end wrench to loosen and remove the pinion nut from the bottom of the driveshaft. Pad handle of the wrench to prevent damage to gear case.

1. Holding socket
2. 11/16 Wrench

Remove the four driveshaft bearing housing screws.

1. Driveshaft bearing housing screws

Remove the driveshaft from the gear case. The bearing housing, shims, thrust bearing, and thrust washer will come out with the driveshaft.

1. Bearing housing
2. Shims
3. Thrust bearing
4. Thrust washer

If driveshaft cannot be removed, refer to Locked Driveshaft Removal on p. 247.Remove the pinion gear from the gear case.

Locked Driveshaft Removal

The driveshaft to pinion taper is a locking taper. If necessary, use Puller, P/N 387206, and Backing Plate, P/N 325867, to break the lock. Install the tools as shown by clamping them around the driveshaft with the tool’s setscrew aligned with the impeller drive key slot. Tighten the setscrew into the slot. Alternately tighten the two vertical screws against the backing plate inserted between the puller and the gear case until the driveshaft pops loose from the pinion.

1. Drive shaft
2. Puller
3. Backing plate

Shift Housing, Gear and Propeller Shaft Removal

Push down on the shift rod. This will move the detent lever downward to clear the inside of the gear case when the shaft assembly is pulled out. Unscrew the shift rod from the detent lever. Remove screws, cover, and shift rod from the gear case.
Discard the cover gasket. Remove and discard the shift rod O-ring from inside of cover.

IMPORTANT: Make sure oil fill/drain plug is removed from gear case.

Remove propeller shaft assembly from gear case.

Pinion Bearing Removal

Inspect the pinion bearing for damage without removing it. If the bearing is removed for any reason, it must be replaced.

If the pinion bearing must be replaced, remove the bearing retaining screw from the gear case. Dis card the O-ring from the screw.

1. Bearing retaining screw

Assemble Pinion Bearing Remover and Installer, P/N 5005927, in the gear case as follows:

1. Flange Nut, P/N 326586 813305
2. Plate, P/N 391260
3. Rod, P/N 326582
4. Remover, P/N 326580

Use a 1 in. wrench to hold the remover in place. Use a 3/4 in. wrench to turn flange nut clockwise and draw the bearing up from the housing.